EP2213790A1 - Roller body for a roller for processing a material and method for producing a roller body - Google Patents
Roller body for a roller for processing a material and method for producing a roller body Download PDFInfo
- Publication number
- EP2213790A1 EP2213790A1 EP10150614A EP10150614A EP2213790A1 EP 2213790 A1 EP2213790 A1 EP 2213790A1 EP 10150614 A EP10150614 A EP 10150614A EP 10150614 A EP10150614 A EP 10150614A EP 2213790 A1 EP2213790 A1 EP 2213790A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- graphite
- roller body
- roller
- peripheral edge
- edge zone
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
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- 238000004519 manufacturing process Methods 0.000 title abstract description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 98
- 239000010439 graphite Substances 0.000 claims abstract description 95
- 229910002804 graphite Inorganic materials 0.000 claims abstract description 95
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 50
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 29
- 239000000956 alloy Substances 0.000 claims abstract description 29
- 229910052742 iron Inorganic materials 0.000 claims abstract description 21
- 239000010451 perlite Substances 0.000 claims abstract description 19
- 235000019362 perlite Nutrition 0.000 claims abstract description 19
- 239000012530 fluid Substances 0.000 claims abstract description 10
- 229910001060 Gray iron Inorganic materials 0.000 claims abstract description 7
- 230000002093 peripheral effect Effects 0.000 claims description 66
- 238000000034 method Methods 0.000 claims description 21
- 229910001018 Cast iron Inorganic materials 0.000 claims description 20
- 238000001816 cooling Methods 0.000 claims description 17
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- 229910052759 nickel Inorganic materials 0.000 claims description 15
- 239000000155 melt Substances 0.000 claims description 14
- 238000004381 surface treatment Methods 0.000 claims description 14
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- 230000008569 process Effects 0.000 claims description 9
- 230000009466 transformation Effects 0.000 claims description 9
- 229910000859 α-Fe Inorganic materials 0.000 claims description 9
- 229910052802 copper Inorganic materials 0.000 claims description 8
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- 238000011282 treatment Methods 0.000 abstract description 10
- 229910001563 bainite Inorganic materials 0.000 abstract description 5
- 238000005266 casting Methods 0.000 description 26
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 24
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- 230000000171 quenching effect Effects 0.000 description 8
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- 239000010949 copper Substances 0.000 description 7
- 239000010703 silicon Substances 0.000 description 7
- 238000005496 tempering Methods 0.000 description 7
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- 229910000831 Steel Inorganic materials 0.000 description 5
- 229910001037 White iron Inorganic materials 0.000 description 5
- 238000005336 cracking Methods 0.000 description 5
- 229910052748 manganese Inorganic materials 0.000 description 5
- 150000001247 metal acetylides Chemical class 0.000 description 5
- 239000010959 steel Substances 0.000 description 5
- 229910052718 tin Inorganic materials 0.000 description 5
- FBPFZTCFMRRESA-FSIIMWSLSA-N D-Glucitol Natural products OC[C@H](O)[C@H](O)[C@@H](O)[C@H](O)CO FBPFZTCFMRRESA-FSIIMWSLSA-N 0.000 description 4
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- 238000007669 thermal treatment Methods 0.000 description 4
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- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 3
- 230000029142 excretion Effects 0.000 description 3
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- 238000007711 solidification Methods 0.000 description 3
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- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F3/00—Press section of machines for making continuous webs of paper
- D21F3/02—Wet presses
- D21F3/08—Pressure rolls
-
- 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
- C21D5/00—Heat treatments of cast-iron
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/04—Cast-iron alloys containing spheroidal graphite
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21G—CALENDERS; ACCESSORIES FOR PAPER-MAKING MACHINES
- D21G1/00—Calenders; Smoothing apparatus
- D21G1/02—Rolls; Their bearings
- D21G1/0246—Hard rolls
Definitions
- the invention relates to a roller body for a roller for the treatment of a material, preferably a thermal or mechanical treatment of a web material. Furthermore, the invention relates to a method for producing such a roll body.
- the roller body may already be part of a roller having at the axial ends of the roller body pin flanges for their pivot bearing.
- the invention also relates to the roll body as such, before it is assembled with other components to form a roll.
- rolls of several meters in length and more than one meter in diameter are used to produce the finished paper web from cellulose sludge by means of thermal and mechanical treatment.
- Rollers made of chilled cast iron, in particular shell-cast iron, or forged steel are used.
- the cast iron bodies are produced by chill casting, usually standing in static chill casting.
- the ring molds is achieved that sets in the outer peripheral edge zone, the shell, a carbide, white cast iron.
- the peripheral edge zone or shell solidifies metastable, white, the carbon is bound there in the form of carbides.
- the melt solidifies in gray the carbon is present as free graphite in the iron matrix.
- the required hardness at the outer circumference of the roll body, the surface hardness, is ensured by the material of the shell, the white cast iron.
- the hardness is set at the surface and in the near-surface depth range.
- the disadvantage of shell casting is the impact brittleness, its sensitivity to sudden changes in temperature, and uneven wear on the outer circumference of the roll due to the carbides contained in the white iron.
- the EP 0 505 343 A1 proposes to overcome the disadvantages mentioned that the roll body is cast from an iron-based alloy, so that a pearlitic or ferritic-pearlitic microstructure is formed which is at least 60% pearlitic.
- the iron-based alloy contains 3.0 - 3.8% C, 1.5 - 3.0% Si and 0.5 - 0.9% Mn. Maximum levels are given for P and S.
- As further alloying elements Cr, Ni, Cu, Mg, Mo, Sn or Al are used.
- the roll body is surface hardened, called induction and flame hardening, and annealed after the martensitic transformation so that the roll body receives a temper martensite structure in its peripheral edge zone. With the martensitic structure of the peripheral edge zone is accompanied by a considerable risk of cracking.
- roller bodies made of forged steel the mentioned material problems can be solved.
- Surface hardness and hardening depth are adjusted on the roll body by subsequent thermal surface treatment.
- the production takes place from a forging block, the weight of which depends on the size of the roll body.
- Roll body as the invention relates to weigh many tons, large roll body, for example, have a weight of about 50 tons or more.
- the weight of the forge block can be up to 200t.
- a hollow forging is possible in this weight range only with great effort.
- high demands are placed on the inner quality of the forged steel with regard to defects, inclusions and the like. The application is therefore very low.
- the roll body should be able to replace the known roll body of shell hard casting, in particular the required hardness on the surface and in the near-surface depth range, but not in the application disadvantageous unevenness in wear and impact brittleness.
- the risk of cracking associated with a martensite shell should also be avoided.
- the invention is based on a roller body which is cast from a single iron-based alloy.
- the iron-base alloy forms in the roll body a radially inner zone of the roll body of gray cast iron, preferably ductile iron, and the inner zone enclosing a the outer periphery of the roller body containing peripheral edge zone having a surface hardness greater than 400HV on the outer circumference, as is the case for the hitherto predominantly used for shell hard casting.
- the roll body can be seen in cross-section of full material, so that the radially inner zone of gray cast iron forms a central core of the roll body.
- the roll body may instead also be a hollow roll shell, so that the radially inner zone is an annular zone.
- the inner zone and the peripheral edge zone are cast in one piece, the use of the two terms is intended to indicate the difference in the microstructure present in the two zones, hereinafter simply microstructure.
- the peripheral edge zone consists either of fine-grained or very fine-grained perlite with vermicular graphite or preferably spheroidal graphite or of an intermediate-layer structure, preferably ADI with spherical or vermicular graphite.
- the fine-grained pearlite is also known as sorbitol and the finest-grained as troostite.
- the invention combines the advantages of the cast roll body with those of the roll body of forged steel and avoids the risk of cracking associated with a martensite shell. As a cast body, it can be made significantly cheaper over its entire axial length in a cast and thus compared to a roll body made of forged steel.
- the gray cast iron inner zone is easy to machine, for example, by cutting.
- near-surface pheripheral holes for the passage of a thermal fluid can be created in the inner zone.
- the hardness profile of the circumferential edge zone that is to say the course of the hardness applied over the roller radius, corresponds at least to the hardness profile of conventional rollers and can be controlled by the heat treatment process.
- the mechanical strength is significantly improved compared to shell casting, which is reflected in higher 0.2% yield strength, tensile strength and elongation at break values.
- the elongation at break is advantageously increased, in particular the risk of cracking is significantly reduced.
- the graphite spheres which form the spheroidal graphite in the solidified peripheral edge zone have a maximum size which corresponds to a guide number of at least 5 (0.06-0.12 mm) according to EN ISO 945 corresponds.
- the excretion of graphite in the form of only such small graphite balls is also advantageous for the mechanical strength and is achieved in the casting process by adjusting the cooling rate of the melt.
- the melt is cooled from the outside, from the outer circumference, wherein the cooling rate is on the one hand so small that sets in the peripheral edge zone to the outer periphery or virtually to the outer periphery of a ductile iron structure, but on the other hand is so large that the Graphite spheres of the peripheral edge zone are smaller than in the conventional nodular cast iron, for example, when poured into a sand mold.
- the nodular graphite has almost only, preferably only, graphite balls having a maximum size which has a guideline value of at least 6 (0.03-0.06 mm), more preferably at least 7 (0.015 mm).
- the graphite spheres of the spheroidal graphite vessel which is preferably also present in the inner zone, can be larger.
- the proportion of spheroidal graphite on the free graphite of the solidified peripheral edge zone is at least 80%, preferably at least 90%, and from the graphite spheres of the spheroidal graphite graphite of the peripheral edge zone correspond to at least 90%, preferably at least 95%, the above requirements for the size of Graphitkugeln. This standard is the currently valid EN ISO 945: 1994.
- the vermicular graphite particles if present, have a maximum size, in this case the length, of 0.12 mm, more preferably at most 0.06 mm, and even more preferably at most 0.03 mm. Of the total vermicular graphite particles present, at least 90%, preferably at least 95%, fall into this size range.
- the carbide content makes up at most 3%.
- Shares in% are always understood as% by mass, ie as% of the total mass. With respect to any carbide content, this means that it is less than 5 mass% of the mass of the peripheral edge zone as a whole, including the carbide portion, preferably at most 3 mass%.
- a white cast iron typically has a carbide content of 15% or more. Also due to the significantly reduced carbide content and the microcrape effect thus reduced, the material of the circumferential edge zone of the roll body according to the invention has significantly improved strength values compared to white cast iron.
- the roll body with the structure according to the invention - radially inner zone in gray cast iron, preferably in spheroidal graphite, and peripheral edge zone in fine or feinststreifigem perlite or as Eisencarengemosge, each with vermicular or preferably nodular graphite - may be part of a roll for the material treatment, either a roller yet outside a machine or a roller already installed in a machine, for example a paper machine.
- the roller accordingly has the roller body and at the two axial ends of the roller body in each case a journal flange for their pivot bearing, optionally the introduction of a torque or the supply or discharge of a thermal fluid.
- journal flanges of a roller this means, for example, that the journal flanges can serve either only the rotary bearing or the rotary bearing and additionally only the introduction of the torque or in a further alternative of the rotary bearing and the supply or discharge of a thermal fluid.
- one of the spigot flanges can fulfill all four functions in combination, ie serve the pivot bearing and initiation of a torque, as well as the supply and discharge of a thermal fluid.
- the invention also relates to a roller body as such, which is provided only for assembly with further components of such a roller, for example the said journal flanges.
- the roll body according to the invention is at least finished insofar as it is no longer subjected to any thermal treatment which specifically serves to adjust the microstructure. Any after-treatment, for example grinding or polishing, optionally machining or, for example, also mechanical training and, in principle, thermal treatments which in particular do not change the structure claimed for the peripheral edge zone to such an extent that it no longer corresponds to the claimed invention. but are excluded from this.
- the roll or the roll body can be used in particular for the thermal or mechanical treatment of a web material, preferably in papermaking, for example as a smoothing or calendering roll.
- the roller or the roller body can also be used as an embossing roll to engrave web material, for example a nonwoven web material.
- Another preferred application is material shredding.
- the roller or the roller body can be used for squeezing, for example, hops or other fruits, in the example as squeezing roller or squeeze roller.
- a method for producing the roll body comprises at least the following steps: the roll body is cast from a melt of an iron-based alloy so that the melt is stable both in the radially inner zone of the roll body and in the radially adjoining peripheral edge zone reaching to the outer periphery Cast iron and solidified at least in the peripheral edge zone, but preferably also in the inner zone in a nodular cast iron structure or a cast structure with vermicular graphite.
- the matrix of the cast iron is pearlitic / ferritic, with the proportion of pearlite being greater than 90% and that of the ferrite being less than 10%.
- the proportion of the perlite of the cast iron matrix is greater than 95% and that of the ferrite is less than 5%.
- any amount of carbide in the peripheral edge zone is less than 5%, preferably less than or equal to or less than 3%.
- the roll body obtained with this cast structure is bonded to the outer periphery by means of a thermal surface treatment, i. hardened on the peripheral surface, and in the peripheral edge zone.
- the thermal surface treatment is carried out so that the peripheral edge zone forming casting material, cast iron with nodular graphite or nodular graphite, with nodular graphite being preferred, is converted into fine or very fine-grained perlite with vermicular or nodular graphite or into an interstage structure with spheroidal graphite or vermicular graphite. More specifically, the cast iron matrix is converted into said perlite or interstage structure, and the free graphite already precipitated by the casting as a stable phase is retained. Further, the melt is not poured into sand, but against mold to control the cooling rate to be able to. Chill casting can be static or instead dynamic, ie centrifugal casting.
- the roll body is expediently poured upright, ie with its longitudinal axis in vertical alignment.
- the casting against mold allows a more precise adjustment of the cooling rate, in particular via the choice of the thickness of the mold measured radially to the longitudinal axis of the roll body, the specific or the absolute heat capacity, the thermal conductivity or the mass of the mold or a suitable combination of such adjustment parameters by the mold.
- the cooling rate can be controlled, for example, by a single or, preferably, a combination of several of the following: lower die thickness, use of a die of a lower heat capacity material , Use of a mold of lower thermal conductivity, lower mold mass, in each case in comparison with a mold for casting a roll body of the same geometry and the same material in conventional hard shell casting.
- the cooling rate is set by cooling the mold not only so small that the melt solidifies stable in the peripheral edge zone, but on the other hand so large that, as explained above for the preferred spheroidal graphite nodular graphite is precipitated in the peripheral edge zone in graphite spheres with a maximum size corresponding to the guideline number 5, preferably a maximum size of the guideline number 6, according to EN ISO 945.
- the graphite balls are particularly preferably in the size range between 7 and 8 according to EN ISO 945, ie at the guideline number 7/8.
- Such a fine graphite precipitation has a positive effect on the mechanical strength.
- the fine precipitation of the graphite also increases the regularity of the surrounding cast iron matrix, which in turn is advantageous for the conversion of this basic structure present after casting into fine-grained or ultraprecipitated perlite or into an interstage structure.
- Due to the thermal surface treatment of the roll body is hardened to a radial depth of advantageously at least 3mm, preferably at least 5mm by the cast iron matrix to at least in this Einhärttiefe in the fine or feinststreifigen perlite or the interstitial structure is converted.
- a Einhärttiefe of 7mm is optimal.
- a hardening depth of more than 10 mm should not be ruled out, large hardening depths produce material tensions when the temperature changes, with the risk that the hardened layer, the peripheral edge zone, will flake off.
- Flame hardening and induction hardening are particularly suitable as methods of thermal surface treatment, preference being given to induction hardening, since flame hardening is limited to the lower part of the hardening depth, generally even below 3 mm. Flame hardening is therefore primarily for roll body with small diameters of up to 600 mm into consideration, although the induction hardening is also given preference here.
- the peripheral edge zone is briefly heated to the austenitic region, preferably to at least 880 ° C. and particularly preferably to about 950 ° C.
- the heated material is cooled by a surface cooling, preferably by means of a water quenching, in a short time to below 100 ° C, preferably below 50 ° C, so that the isothermal conversion takes place in the fine or feinststreifigen perlite.
- a surface cooling preferably by means of a water quenching
- a higher cooling rate is set, but still not so large that a significant martensitic transformation takes place. Martensite is ideally avoided because of the associated risk of cracking.
- the cast iron of the peripheral edge zone therefore has, in preferred embodiments, a martensite start temperature M s which is below the values given above, ie below 100 ° C., preferably below 50 ° C.
- the material of the peripheral edge zone has a martensite start temperature M s which is below room temperature, ie below 20 ° C.
- the surface hardened roll body is advantageously tempered to relieve stresses.
- the tempering temperature is above the temperature that reaches the roller body in later operation at the most, advantageously above 30 ° C, preferably a tempering temperature in the range of 300 to 350 ° C. Even after such an annealing, the roll body in the peripheral edge zone on the fine or feinststreifg pearlitic structure with spherical or vermicular graphite or the interstage structure with spherical or vermicular graphite.
- the iron-base alloy has a carbon content of preferably at least 3%, preferably at most 4%.
- the silicon content is preferably at least 1.7 and preferably at most 2.4%, whereby these are also always% by mass.
- the degree of saturation Sc of the alloy is preferably in the range of 0.97 to 1.03, preferably it is slightly smaller than 1.0, so that the melt is slightly hypoeutectic.
- a preferred alloying partner is copper, as a perlite former, and in a proportion of preferably at least 0.5 and preferably at most 1.3%.
- a particularly preferred alloying partner is also nickel, which is alloyed in a proportion of preferably more than 0.3%, more preferably more than 0.5%, and preferably at most 1.5%. Nickel increases the toughness and makes the material corrosion-resistant.
- nickel is of particular value for preventing martensite transformation during curing. If the iron base alloy contains both silicon and nickel, it is advantageous if the silicon content decreases with increasing nickel content and the nickel content decreases with increasing silicon content. Preference is given to a silicon content from the lower half of the range specified for silicon and a nickel content from the middle part of the range specified for nickel.
- a particularly preferred iron alloy contains as alloying partners both Ni and Cu with preferably at least the minimum proportions indicated for each.
- Optional alloying partners are also manganese and tin, manganese preferably in the range of 0.3 to 0.45%, tin preferably in the range of 0.005 to 0.015%. Compared to the other alloying elements mentioned above, however, the meaning of manganese and tin is reversed.
- a preferred iron-based alloy contains C, Si, Ni and Cu within the preferred limits of the proportions, optionally Mn and Sn, as well as unavoidable residual P and S and the remainder Fe. Any proportions of phosphorus and sulfur are advantageously each well below 0.1%, more preferably still well below 0.05%.
- FIG. 1 shows a roller for the treatment of a web material, for example a calender roll, with a roller body 1 and two flange pins 2 and 3, one of which is mounted on the left and the other on the right front side of the roller body 1.
- the roller is rotatably mounted in the region of the journal flanges 2 and 3 about an axis of rotation R or provided for pivotal mounting.
- a thermal fluid can be supplied, which can be derived via the other or preferably the same pin flange 2 or 3 again.
- the roller body 1 passes through from one axial end to the other continuous, located near the outer periphery of the roller body 1, peripheral tempering 4, which are flowed through during the thermal treatment of the material from the thermal fluid.
- FIG. 2 shows the roller body 1 in cross section AA.
- the roller body 1 is a cast body. It is poured by gravity casting, for example in static chill casting, standing from a melt of an iron-based alloy. The central cavity is formed or incorporated later in this Urformung. As the iron-base alloy, a cast iron alloy is used. The cooling, which undergoes the melt primarily on the mold, is controlled so that the melt over the entire axial length of the roll body 1 from radially inward to radially outward to the outer circumference or almost to the outer circumference stably solidified in a ductile iron structure, ie in the form of a cast iron with nodular graphite.
- the control of the cooling is done by customized design of the mold.
- the cooling rate can be adjusted in particular via the radial thickness of the mold, the heat capacity of the mold, the thermal conductivity of the mold material or the total mass of the mold.
- the mold can be designed only with respect to a single of said parameters or a combination of two, three or all four of these parameters by appropriate material selection and dimensioning.
- the solidification process is controlled so that the melt solidly solidifies not only in an inner zone 5 surrounding the rotation axis R, but also in a peripheral edge zone 6 enclosing the inner zone 5, which forms the outer circumference of the roll body.
- the roller body 1 thus solidifies over its entire cross-section stable and not white.
- the carbon is eliminated in the stable solidification in the form of nodular graphite.
- the directly obtained by the casting process roller body 1 thus has everywhere a ductile iron structure. Due to the cooling rate set deliberately by means of the mold, however, the graphite in the peripheral edge zone 1 separates out more finely than in the inner zone 5.
- the graphite spherulites SG (sphero-graphite particles) of the peripheral edge zone 6 have a size in the range of the guide numbers of 5 to 8, ie a maximum dimension of at most 0.12 mm. More preferably, the cooling rate is set so that the graphite particles SG of the peripheral edge zone 6 have a size in the range of the guide numbers of 7 (0.022 microns) to 8 according to EN ISO 945, ie a maximum dimension of at most 0.03 mm.
- the cast iron matrix is also in the peripheral edge zone 6 perlitic with at most a low ferrite content.
- the pearlite content is at least 90%, more preferably at least 95%, and the ferrite content at most 10%, more preferably at most 5%. If carbide formation can not be prevented, the carbide content is less than 5%, more preferably less than 3%, not only in the inner zone 5 but also in the peripheral edge zone 6 solidified at a higher cooling rate.
- FIG. 3 shows a part of the FIG. 2 and further, extracted, a further enlarged view of the microstructure of the roll body obtained by the casting.
- These are the fineness of the excreted graphite particles SG
- the microstructure shown next to the cross section of the roller body 1 are primarily schematic in nature, but qualitatively illustrate that the graphite particles SG in the peripheral edge zone 6 are smaller than the graphite particles SG in the inner zone 5 and in the peripheral edge zone 6 correspondingly in finer distribution.
- the roll body 1 is made wear-resistant in its subsequent higher-hardness peripheral edge zone 6 already obtained by the casting in a subsequent hardening process.
- the peripheral tempering 4 are incorporated, preferably drilled.
- the peripheral edge zone 6 is understood to be that annular zone of the roller body 1 which, after hardening, has the hardness required for the respective application everywhere, ie extends from the outer circumference to the hardening depth. If the peripheral edge zone 6 of the hardened roll body 1 extends radially inwardly up to or even over the tempering channels 4, these are expediently incorporated before hardening. Otherwise, the tempering 4 can just as well be incorporated after curing.
- the hardening process is carried out in such a way that the basic structure of the peripheral edge zone 6 obtained directly from the casting is converted into finely striated or, even more advantageously, finely striated perlite.
- the graphite spherulites SG are thereby not or at least not changed in a manner relevant to the invention.
- the hardening process can also be designed such that the cast iron matrix within the peripheral edge zone 6 is converted into an interstage structure, preferably in the form of austempered ductile iron (ADI).
- ADI austempered ductile iron
- the roll body 1 in the peripheral edge zone 6 is uniformly heated to a temperature in the austenitic region, for example at 950 ° C., and then quenched, the quenching rate for forming an interstage structure being set higher than for fine perlite transformation, but still not so big that a martensite transformation can take place.
- the interstitial structure is similar to bainite, preferably the lower bainite, but is not bainite because it contains no or, for the desired strength, only negligible carbides. It is also true for the interstitial structure that the carbide fraction is advantageously less than 5%, preferably at most 3%. is. For the purposes of the invention, it would be ideal if neither the fine-pearlitic structure nor the alternative interstitial structure would contain carbides.
- FIG. 4 illustrates a curing process using the example of the preferred induction hardening.
- an induction device 8 and a quenching device 9 are moved axially from one end face of the roller body 1 to the other.
- the movement is uniform with the speed v and a constant during the hardening process axial distance x, by which the induction device 8 precedes the quenching device 9.
- the roller body 1 is uniformly heated to the predetermined hardening depth, ie within the peripheral edge zone 6, throughout the temperature range mentioned above and then quenched by means of the quenching device 9.
- the quenching is preferably carried out with a liquid quenching fluid, for example water, which is injected onto the outer circumference of the roller body 1.
- the peripheral edge zone 6 may in principle be heated by any other thermal surface treatment method as long as only the required temperature is adjusted with the required uniformity.
- induction hardening in particular flame hardening comes into consideration, but primarily only for lower hardening depths. As hardening depth increases, induction hardening is the preferred choice.
- the hardening depth and, accordingly, the thickness of the peripheral edge zone 6 are preferably at least 3 mm, more preferably at least 5 mm. On the other hand, it is advantageous in terms of thermal cycling, if the Einhärttiefe does not exceed 10mm.
- the hardening depth can be influenced in particular by a variation of the distance x, in the case of induction hardening also by varying the frequency of the respective induction coil 8. Further adjusting parameters for influencing the hardening depth are the speed v, the choice of the Abschreekfluids and the throughput of quenching fluid.
- FIGS. 5 and 6 are micrographs of the structure of the peripheral edge zone.
- FIG. 5 shows the basic structure obtained directly from the casting in the scale 50: 1
- FIG. 6 is a Micrograph of the microstructure after curing, thus showing the hardness structure, also in the scale 50: 1.
- the graphite spheres or graphitic spherolites are denoted by SG, the perlite by P and ferrite islands by ⁇ .
- the basic structure consists essentially of perlite and precipitated nodular graphite and small amounts of ferrite, less than 10% ferrite in the exemplary embodiment.
- the hardness structure consists of fine-grained and very fine-grained pearlite, ie sorbitol and troostite, as well as the embedded sphero-graphite particles SG, the pearlite areas being designated S for sorbitol and T for troostite according to the fineness of the lamellae.
- FIG. 7 the microhardness curve is shown for a given hardening depth of 3 mm, namely the hardness H in HV0.1 over the distance d from the outer circumference of the roll body 1, that is to say over the depth d.
- the hardened roll body 1 is tempered, advantageously to a tempering temperature of between 300 and 350 ° C.
- a particularly preferred iron-base alloy for casting the roll body 1 is specified in the last column of the table.
- the second and third columns contain preferred ranges for the respective alloying partner, with the narrower ranges within the respective wider range being particularly preferred for the same alloying element.
- the proportion specified in the last column is most preferred.
- the iron-based alloy contains in a preferred embodiment at least carbon, silicon, copper and nickel within the respective specified ranges of shares. Copper as a perlite former and nickel to prevent martensite transformation are preferably used in combination. Fe makes up the rest of the respective alloy.
- the iron base melt of the composition of the last column has a saturation degree Sc of 0.99 to 1.00. Preference is given to iron-base alloys having a degree of saturation Sc in the range from 0.97 to 1.03, from which range of alloys of near-tectic composition those having a degree of saturation Sc from the lower half of the stated range are preferred.
- the roller body 1 of the embodiment is solidified in a nodular cast iron structure.
- the embedded free graphite in the inner zone 5 and also in the peripheral edge zone 6 may be excreted substantially in the form of vermicular graphite or else in the form of spheroidal graphite and vermicular graphite.
- the excretion of nodular graphite is given preference over the excretion of vermicular graphite.
- the free graphite as nodular graphite and as Vermikulargraphit it is advantageous if the nodular graphite accounts for the majority of the free graphite.
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Abstract
Description
Die Erfindung betrifft einen Walzenkörper für eine Walze zur Behandlung eines Materials, vorzugsweise eine thermische oder mechanische Behandlung eines Bahnmaterials. Ferner betrifft die Erfindung ein Verfahren zur Herstellung solcher Walzenkörper. Der Walzenkörper kann bereits Bestandteil einer Walze sein, die an den axialen Enden des Walzenkörpers Zapfenflansche für ihre Drehlagerung aufweist. Die Erfindung betrifft den Walzenkörper aber auch als solchen, bevor er mit weiteren Komponenten zu einer Walze zusammengebaut wird.The invention relates to a roller body for a roller for the treatment of a material, preferably a thermal or mechanical treatment of a web material. Furthermore, the invention relates to a method for producing such a roll body. The roller body may already be part of a roller having at the axial ends of the roller body pin flanges for their pivot bearing. The invention also relates to the roll body as such, before it is assembled with other components to form a roll.
In der Papierherstellung, einer bevorzugten Anwendung erfindungsgemäßer Walzenkörper, werden Walzen von mehreren Metern Länge und mehr als einem Meter Durchmesser verwendet, um aus Celluloseschlamm mittels thermischer und mechanischer Behandlung die fertige Papierbahn herzustellen. Zum Einsatz kommen Walzen aus Hartguss, insbesondere Schalenhartguss, oder Schmiedestahl. Die Walzenkörper aus Hartguss werden im Kokillengussverfahren hergestellt, zumeist stehend im statischen Kokillenguss. Durch die Ringkokillen wird erreicht, dass sich in der äußeren Umfangsrandzone, der Schale, ein karbidisches, weißes Gusseisen einstellt. Die Umfangsrandzone beziehungsweise Schale erstarrt metastabil, weiß, der Kohlenstoff ist dort in Form von Karbiden gebunden. Im Kern kommt es zu einer stabilen Erstarrung, die Schmelze erstarrt dort grau, der Kohlenstoff liegt als freier Graphit in der Eisen-Matrix vor. Die erforderliche Härte am äußeren Umfang des Walzenkörpers, die Oberflächenhärte, wird von dem Werkstoff der Schale, dem weißen Gusseisen gewährleistet. Über die Kokille und die Legierungselemente der Eisenbasisschmelze wird die Härte an der Oberfläche und im oberflächennahen Tiefenbereich eingestellt. Nachteilig wirken sich beim Schalenhartguss die Schlagsprödigkeit, eine Empfindlichkeit gegenüber plötzlichen Temperaturänderungen und ein aufgrund der im Weißeisen enthaltenen Karbide ungleichmäßiger Verschleiß am äußeren Walzenumfang aus.In papermaking, a preferred application of roll bodies according to the invention, rolls of several meters in length and more than one meter in diameter are used to produce the finished paper web from cellulose sludge by means of thermal and mechanical treatment. Rollers made of chilled cast iron, in particular shell-cast iron, or forged steel are used. The cast iron bodies are produced by chill casting, usually standing in static chill casting. By the ring molds is achieved that sets in the outer peripheral edge zone, the shell, a carbide, white cast iron. The peripheral edge zone or shell solidifies metastable, white, the carbon is bound there in the form of carbides. At its core, solidification takes place, the melt solidifies in gray, the carbon is present as free graphite in the iron matrix. The required hardness at the outer circumference of the roll body, the surface hardness, is ensured by the material of the shell, the white cast iron. By means of the mold and the alloy elements of the iron base melt, the hardness is set at the surface and in the near-surface depth range. The disadvantage of shell casting is the impact brittleness, its sensitivity to sudden changes in temperature, and uneven wear on the outer circumference of the roll due to the carbides contained in the white iron.
Die
Mit der Eingangs genannten Alternative, Walzenkörper aus Schmiedestahl, können die genannten Materialprobleme gelöst werden. Oberflächenhärte und Einhärttiefe werden am Walzenkörper durch nachträgliche thermische Oberflächenbehandlung eingestellt. Die Herstellung erfolgt allerdings aus einem Schmiedeblock, dessen Gewicht von der Größe des Walzenkörpers abhängt. Walzenkörper, wie die Erfindung sie betrifft, wiegen viele Tonnen, große Walzenkörper haben beispielsweise ein Gewicht von etwa 50t oder auch mehr. Für derartige Walzenkörper kann das Gewicht des Schmiedblocks bis zu 200t betragen. Ein Hohlschmieden ist in diesem Gewichtsbereich nur mit sehr hohem Aufwand möglich. Zusätzlich werden hohe Anforderungen an die innere Güte des Schmiedestahls hinsichtlich Fehlstellen, Einschlüssen und dergleichen gestellt. Das Ausbringen ist daher sehr gering.With the mentioned alternative, roller bodies made of forged steel, the mentioned material problems can be solved. Surface hardness and hardening depth are adjusted on the roll body by subsequent thermal surface treatment. However, the production takes place from a forging block, the weight of which depends on the size of the roll body. Roll body, as the invention relates to weigh many tons, large roll body, for example, have a weight of about 50 tons or more. For such roll body, the weight of the forge block can be up to 200t. A hollow forging is possible in this weight range only with great effort. In addition, high demands are placed on the inner quality of the forged steel with regard to defects, inclusions and the like. The application is therefore very low.
Es ist eine Aufgabe der Erfindung, einen Walzenkörper mit gegenüber Schalenhartguss verbesserten mechanischen Eigenschaften zu günstigem Preis bereitzustellen. Der Walzenkörper soll die bekannten Walzenkörper aus Schalenhartguss ersetzen können, insbesondere die geforderte Härte an der Oberfläche und auch im oberflächennahen Tiefenbereich, allerdings nicht die in der Anwendung nachteilige Ungleichmäßigkeit im Verschleiß und Schlagsprödigkeit aufweisen. Die mit einer Martensitschale einhergehende Rissgefahr soll ebenfalls vermieden werden.It is an object of the invention to provide a roller body with improved mechanical properties at a favorable price compared with shell-hard casting. The roll body should be able to replace the known roll body of shell hard casting, in particular the required hardness on the surface and in the near-surface depth range, but not in the application disadvantageous unevenness in wear and impact brittleness. The risk of cracking associated with a martensite shell should also be avoided.
Die Erfindung geht von einem Walzenkörper aus, der aus einer einzigen Eisenbasislegierung gegossen ist. Die Eisenbasislegierung bildet im Walzenkörper eine radial innere Zone des Walzenkörpers aus grauem Gusseisen, vorzugsweise Sphäroguss, und die innere Zone umschließend eine den äußeren Umfang des Walzenkörpers enthaltende Umfangsrandzone, die am äußeren Umfang eine Oberflächenhärte größer als 400HV aufweist, wie dies auch für den bislang überwiegend zur Anwendung gelangenden Schalenhartguss der Fall ist. Der Walzenkörper kann im Querschnitt gesehen aus vollem Material bestehen, so dass die radial innere Zone aus grauem Gusseisen einen zentralen Kern des Walzenkörpers bildet. Der Walzenkörper kann stattdessen auch ein hohler Walzenmantel sein, so dass die radial innere Zone eine Ringzone ist. Die innere Zone und die Umfangsrandzone werden in einem Stück gegossen, die Verwendung der beiden Begriffe soll auf die Unterschiedlichkeit der in den beiden Zonen vorliegenden Mikrogefüge, im folgenden einfach Gefüge, hindeuten.The invention is based on a roller body which is cast from a single iron-based alloy. The iron-base alloy forms in the roll body a radially inner zone of the roll body of gray cast iron, preferably ductile iron, and the inner zone enclosing a the outer periphery of the roller body containing peripheral edge zone having a surface hardness greater than 400HV on the outer circumference, as is the case for the hitherto predominantly used for shell hard casting. The roll body can be seen in cross-section of full material, so that the radially inner zone of gray cast iron forms a central core of the roll body. The roll body may instead also be a hollow roll shell, so that the radially inner zone is an annular zone. The inner zone and the peripheral edge zone are cast in one piece, the use of the two terms is intended to indicate the difference in the microstructure present in the two zones, hereinafter simply microstructure.
Nach der Erfindung besteht die Umfangsrandzone entweder aus feinstreifigem oder feinststreifigem Perlit mit Vermikulargraphit oder vorzugsweise Kugelgraphit oder aus einem Zwischenstufengefüge, vorzugsweise ADI mit Kugel- oder Vermikulargraphit. Den feinstreifigen Perlit bezeichnet man auch als Sorbit und den feinststreifigen als Troostit. Die Erfindung vereint die Vorteile der Gusswalzenkörper mit denen der Walzenkörper aus Schmiedestahl und vermeidet die mit einer Martensitschale einhergehende Rissgefahr. Als Gusskörper kann sie über ihre gesamte axiale Länge in einem Guss und somit im Vergleich zu einem Walzenkörper aus Schmiedestahl deutlich preiswerter hergestellt werden. Die aus grauem Gusseisen bestehende innere Zone lässt sich gut bearbeiten, beispielsweise spanend. So können in der inneren Zone oberflächennah pheriphere Bohrungen für die Durchleitung eines Thermalfluids geschaffen werden. Das Härteprofil der Umfangsrandzone, das heißt der über dem Walzenradius aufgetragene Verlauf der Härte, entspricht zumindest dem Härteprofil konventioneller Walzen und kann durch den Wärmebehandlungsprozess gesteuert werden. Die mechanische Festigkeit ist im Vergleich zum Schalenhartguss jedoch deutlich verbessert, was sich in höheren Werten für die 0.2% - Dehngrenze, die Zugfestigkeit und die Bruchdehnung ausdrückt. Gegenüber einem Anlassmartensitgefüge ist die Bruchdehnung vorteilhafterweise erhöht, insbesondere ist die Rissgefahr deutlich verringert.According to the invention, the peripheral edge zone consists either of fine-grained or very fine-grained perlite with vermicular graphite or preferably spheroidal graphite or of an intermediate-layer structure, preferably ADI with spherical or vermicular graphite. The fine-grained pearlite is also known as sorbitol and the finest-grained as troostite. The invention combines the advantages of the cast roll body with those of the roll body of forged steel and avoids the risk of cracking associated with a martensite shell. As a cast body, it can be made significantly cheaper over its entire axial length in a cast and thus compared to a roll body made of forged steel. The gray cast iron inner zone is easy to machine, for example, by cutting. Thus, near-surface pheripheral holes for the passage of a thermal fluid can be created in the inner zone. The hardness profile of the circumferential edge zone, that is to say the course of the hardness applied over the roller radius, corresponds at least to the hardness profile of conventional rollers and can be controlled by the heat treatment process. However, the mechanical strength is significantly improved compared to shell casting, which is reflected in higher 0.2% yield strength, tensile strength and elongation at break values. Compared to a tempered martensite, the elongation at break is advantageously increased, in particular the risk of cracking is significantly reduced.
In bevorzugten Ausführungen, in denen der freie Graphit der Umfangsgrundzone zumindest im Wesentlichen als Kugelgraphit vorliegt, haben die Graphitkugeln, die den Kugelgraphit in der erstarrten Umfangsrandzone bilden, maximal eine Größe, die einer Richtzahl von wenigstens 5 (0.06 - 0.12 mm) nach EN ISO 945 entspricht. Die Ausscheidung des Graphits in Form nur solch kleiner Graphitkugeln ist ebenfalls vorteilhaft für die mechanische Festigkeit und wird im Gießprozess durch Einstellung der Abkühlgeschwindigkeit der Schmelze erzielt. Die Schmelze wird hierfür von Außen, vom äußeren Umfang her, gekühlt, wobei die Abkühlgeschwindigkeit einerseits so klein ist, dass sich in der Umfangsrandzone bis zum äußeren Umfang oder bis praktisch zum äußeren Umfang ein Sphärogussgefüge einstellt, andererseits aber doch so groß ist, dass die Graphitkugeln der Umfangsrandzone kleiner sind als beim herkömmlichen Sphäroguss, beispielsweise beim Gießen in eine Sandform. Besonders vorteilhaft ist es, wenn in dem durch den Guss in der Umfangsrandzone erhaltenen Grundgefüge der Kugelgraphit nahezu nur, vorzugsweise nur Graphitkugeln mit einer maximalen Größe aufweist, die einer Richtzahl von wenigstens 6 (0.03 - 0.06 mm), noch besser wenigstens 7 (0.015 - 0.03 mm) nach EN ISO 945 aufweist. Die Graphitkugeln des bevorzugt auch in der inneren Zone vorliegenden Sphärogussgefdges können demgegenüber größer sein. In den erläuterten bevorzugten Ausführungen beträgt der Anteil des Kugelgraphits am freien Graphit der erstarrten Umfangsrandzone wenigstens 80%, bevorzugt wenigstens 90%, und von den Graphitkugeln des Kugelgraphits der Umfangsrandzone entsprechen wenigstens 90%, vorzugsweise wenigstens 95%, den vorstehenden Vorgaben für die Größe der Graphitkugeln. Bei der genannten Norm handelt es sich um die zur Zeit gültige EN ISO 945:1994. Soweit der freie Graphit in Vermikularform ausgeschieden ist, gelten für die Vermikular-Graphitteilchen die genannten Angaben zur Größe und den prozentualen Anteilen ebenfalls. Demgemäß weisen die Vermikular-Graphitteilchen, soweit vorhanden, in bevorzugten Ausführungen eine maximale Größe auf, in diesem Fall die Länge, von 0.12 mm, bevorzugter höchstens 0.06 mm und noch bevorzugter höchstens 0.03 mm. Von den insgesamt vorhandenen Vermikular-Graphitteilchen fallen wenigstens 90%, vorzugsweise wenigstens 95%, in diesen Größenbereich.In preferred embodiments, in which the free graphite of the circumferential base zone is present at least essentially as spheroidal graphite, the graphite spheres which form the spheroidal graphite in the solidified peripheral edge zone have a maximum size which corresponds to a guide number of at least 5 (0.06-0.12 mm) according to EN ISO 945 corresponds. The excretion of graphite in the form of only such small graphite balls is also advantageous for the mechanical strength and is achieved in the casting process by adjusting the cooling rate of the melt. For this purpose, the melt is cooled from the outside, from the outer circumference, wherein the cooling rate is on the one hand so small that sets in the peripheral edge zone to the outer periphery or virtually to the outer periphery of a ductile iron structure, but on the other hand is so large that the Graphite spheres of the peripheral edge zone are smaller than in the conventional nodular cast iron, for example, when poured into a sand mold. It is particularly advantageous if, in the basic structure obtained by the casting in the peripheral edge zone, the nodular graphite has almost only, preferably only, graphite balls having a maximum size which has a guideline value of at least 6 (0.03-0.06 mm), more preferably at least 7 (0.015 mm). 0.03 mm) according to EN ISO 945. In contrast, the graphite spheres of the spheroidal graphite vessel, which is preferably also present in the inner zone, can be larger. In the illustrated preferred embodiments, the proportion of spheroidal graphite on the free graphite of the solidified peripheral edge zone is at least 80%, preferably at least 90%, and from the graphite spheres of the spheroidal graphite graphite of the peripheral edge zone correspond to at least 90%, preferably at least 95%, the above requirements for the size of Graphitkugeln. This standard is the currently valid EN ISO 945: 1994. As far as the free graphite is excreted in vermicular form, the information given on the size and the percentage proportions also apply to the vermicular graphite particles. Accordingly, in preferred embodiments, the vermicular graphite particles, if present, have a maximum size, in this case the length, of 0.12 mm, more preferably at most 0.06 mm, and even more preferably at most 0.03 mm. Of the total vermicular graphite particles present, at least 90%, preferably at least 95%, fall into this size range.
Soweit das Gefüge der Umfangsrandzone überhaupt Karbide aufweist, liegt deren Anteil unter 5%, bevorzugt macht der Karbidanteil höchstens 3% aus. Anteilsangaben in % werden stets als Masse-%, d.h. als %-Anteil an der jeweiligen Gesamtmasse verstanden. In Bezug auf einen etwaigen Karbidanteil bedeutet dies, dass dieser von der Masse der Umfangsrandzone im Ganzen, einschließlich des Karbidanteils, weniger als 5 Massen-% ausmacht, bevorzugt höchstens 3 Massen-% beträgt. Zum Vergleich: Ein weißes Gusseisen hat typischerweise einen Karbidanteil von 15% und mehr. Auch aufgrund des deutlich verringerten Karbidanteils und der deshalb verringerten Mikrokerbwirkung weist der Werkstoff der Umfangsrandzone des erfindungsgemäßen Walzenkörpers im Vergleich zum weißen Gusseisen deutlich verbesserte Festigkeitswerte auf.As far as the structure of the peripheral edge zone has at all carbides, their proportion is less than 5%, preferably the carbide content makes up at most 3%. Shares in% are always understood as% by mass, ie as% of the total mass. With respect to any carbide content, this means that it is less than 5 mass% of the mass of the peripheral edge zone as a whole, including the carbide portion, preferably at most 3 mass%. By comparison, a white cast iron typically has a carbide content of 15% or more. Also due to the significantly reduced carbide content and the microcrape effect thus reduced, the material of the circumferential edge zone of the roll body according to the invention has significantly improved strength values compared to white cast iron.
Der Walzenkörper mit der erfindungsgemäßen Struktur - radial innere Zone in Grauguss, bevorzugt in Sphäroguss, und Umfangsrandzone in fein- oder feinststreifigem Perlit oder als Zwischenstufengefüge, jeweils mit Vermikular- oder bevorzugt Kugelgraphit - kann Bestandteil einer Walze für die Materialbehandlung sein, entweder einer Walze noch außerhalb einer Maschine oder einer bereits in einer Maschine, beispielsweise Papiermaschine, eingebauten Walze. Die Walze weist dementsprechend den Walzenkörper und an den beiden axialen Enden des Walzenkörpers jeweils einen Zapfenflansch für ihre Drehlagerung, optional die Einleitung eines Drehmoments oder die Zu- oder Abführung eines Thermalfluids auf Das Wort "oder" wird im üblichen logischen Sinne und somit als ein "inclusive oder" verstanden, umfasst also sowohl die Bedeutung von "entweder...oder" als auch die Bedeutung von "und", soweit sich aus dem jeweils konkreten Zusammenhang nicht ausschließlich nur eine eingeschränkte Bedeutung erschließt. Bezogen auf die Zapfenflansche einer Walze bedeutet dies beispielsweise, dass die Zapfenflansche entweder nur der Drehlagerung oder der Drehlagerung und zusätzlich nur der Einleitung des Drehmoments oder in einer weiteren Alternative der Drehlagerung und der Zu- oder Abführung eines Thermalfluids dienen können. Des Weiteren kann beispielsweise einer der Zapfenflansche alle vier Funktionen in Kombination erfüllen, d.h. der Drehlagerung und Einleitung eines Drehmoments, sowie der Zu- und Abführung eines Thermalfluids dienen. Die Erfindung betrifft auch einen Walzenkörper als solchen, der erst für den Zusammenbau mit weiteren Komponenten solch einer Walze vorgesehen ist, beispielsweise den genannten Zapfenflanschen. Der erfindungsgemäße Walzenkörper ist zumindest insoweit fertig als er keiner thermischen Behandlung mehr unterworfen wird, die gezielt der Einstellung des Mikrogefüges dient. Eine etwaige Nachbehandlung, beispielsweise ein Schleifen oder Polieren, optional eine spanende Bearbeitung oder beispielsweise auch ein mechanisches Trainieren und grundsätzlich auch thermische Behandlungen, die insbesondere das für die Umfangsrandzone beanspruchte Gefüge nicht in solch einem Ausmaß ändern, dass es nicht mehr der beanspruchten Erfindung entspricht, sind hiervon allerdings ausgenommen.The roll body with the structure according to the invention - radially inner zone in gray cast iron, preferably in spheroidal graphite, and peripheral edge zone in fine or feinststreifigem perlite or as Zwischenstufengefüge, each with vermicular or preferably nodular graphite - may be part of a roll for the material treatment, either a roller yet outside a machine or a roller already installed in a machine, for example a paper machine. The roller accordingly has the roller body and at the two axial ends of the roller body in each case a journal flange for their pivot bearing, optionally the introduction of a torque or the supply or discharge of a thermal fluid. The word "or" is used in the usual logical sense and thus as a " inclusive or "understood, ie includes both the meaning of" either ... or "as well as the meaning of" and ", as far as from the particular concrete context not exclusively opens only a limited meaning. With reference to the journal flanges of a roller, this means, for example, that the journal flanges can serve either only the rotary bearing or the rotary bearing and additionally only the introduction of the torque or in a further alternative of the rotary bearing and the supply or discharge of a thermal fluid. Furthermore, for example, one of the spigot flanges can fulfill all four functions in combination, ie serve the pivot bearing and initiation of a torque, as well as the supply and discharge of a thermal fluid. The invention also relates to a roller body as such, which is provided only for assembly with further components of such a roller, for example the said journal flanges. The roll body according to the invention is at least finished insofar as it is no longer subjected to any thermal treatment which specifically serves to adjust the microstructure. Any after-treatment, for example grinding or polishing, optionally machining or, for example, also mechanical training and, in principle, thermal treatments which in particular do not change the structure claimed for the peripheral edge zone to such an extent that it no longer corresponds to the claimed invention. but are excluded from this.
Die Walze beziehungsweise der Walzenkörper kann insbesondere für die thermische oder mechanische Behandlung eines Bahnmaterials, vorzugsweise in der Papierherstellung, verwendet werden, beispielsweise als Glätt- oder Kalanderwalze. In der Behandlung von Bahnmaterial kann die Walze beziehungsweise der Walzenkörper auch als Prägewalze verwendet werden, um Bahnmaterial mit einer Gravur zu versehen, beispielsweise ein nonwoven Bahnmaterial. Eine weitere bevorzugte Anwendung ist die Materialzerkleinerung. So kann die Walze beziehungsweise der Walzenkörper zum Quetschen beispielsweise von Hopfen oder anderen Früchten verwendet werden, im Beispielfall als Quetschwalze beziehungsweise Quetschwalzenkärper.The roll or the roll body can be used in particular for the thermal or mechanical treatment of a web material, preferably in papermaking, for example as a smoothing or calendering roll. In the treatment of web material, the roller or the roller body can also be used as an embossing roll to engrave web material, for example a nonwoven web material. Another preferred application is material shredding. Thus, the roller or the roller body can be used for squeezing, for example, hops or other fruits, in the example as squeezing roller or squeeze roller.
Ein Verfahren zur Herstellung des Walzenkörpers umfasst zumindest die folgenden Schritte: der Walzenkörper wird aus einer Schmelze einer Eisenbasislegierung gegossen, so dass die Schmelze sowohl in der radial inneren Zone des Walzenkörpers als auch in der sich radial anschließenden und bis zum äußeren Umfang reichenden Umfangsrandzone stabil als Gusseisen und zumindest in der Umfangsrandzone, bevorzugt aber auch in der inneren Zone in einem Sphärogussgefüge oder einem Gussgefüge mit Vermikulargraphit erstarrt. Die Matrix des Gusseisens ist perlitisch/ferritisch, wobei der Anteil des Perlits größer als 90% und der des Ferrits kleiner als 10% sein sollte. Bevorzugt ist der Anteil des Perlits der Gusseisenmatrix größer als 95% und der des Ferrits kleiner als 5%. Ein etwaiger Karbidanteil ist in der Umfangsrandzone kleiner als 5%, vorzugsweise kleiner oder höchstens gleich 3%. Der mit diesem Gussgefüge erhaltene Walzenkörper wird mittels einer thermischen Oberflächenbehandlung am äußeren Umfang, d.h. an der Umfangsoberfläche, und in der Umfangsrandzone gehärtet.A method for producing the roll body comprises at least the following steps: the roll body is cast from a melt of an iron-based alloy so that the melt is stable both in the radially inner zone of the roll body and in the radially adjoining peripheral edge zone reaching to the outer periphery Cast iron and solidified at least in the peripheral edge zone, but preferably also in the inner zone in a nodular cast iron structure or a cast structure with vermicular graphite. The matrix of the cast iron is pearlitic / ferritic, with the proportion of pearlite being greater than 90% and that of the ferrite being less than 10%. Preferably, the proportion of the perlite of the cast iron matrix is greater than 95% and that of the ferrite is less than 5%. Any amount of carbide in the peripheral edge zone is less than 5%, preferably less than or equal to or less than 3%. The roll body obtained with this cast structure is bonded to the outer periphery by means of a thermal surface treatment, i. hardened on the peripheral surface, and in the peripheral edge zone.
Nach der Erfindung wird die thermische Oberflächenbehandlung so durchgeführt, dass der die Umfangsrandzone bildende Gusswerkstoff, Gusseisen mit Vermiluargraphit oder Kugelgraphit, wobei Kugelgraphit bevorzugt wird, in fein- oder feinststreifigen Perlit mit Vermikular- oder Kugelgraphit oder in ein Zwischenstufengefüge mit Kugelgraphit oder Vermikulargraphit umgewandelt wird. Genauer gesagt wird die Gusseisenmatrix in den genannten Perlit oder das Zwischenstufengefüge umgewandelt, und der bereits durch den Guss als stabile Phase ausgeschiedene freie Graphit bleibt erhalten. Die Schmelze wird ferner nicht in Sand gegossen, sondern gegen Kokille, um die Abkühlgeschwindigkeit kontrollieren zu können. Der Kokillenguss kann statisch oder stattdessen auch dynamisch, also als Schleudergussverfahren, durchgeführt werden. Der Walzenkörper wird zweckmäßigerweise stehend, also mit seiner Längsachse in vertikaler Ausrichtung, gegossen. Der Guss gegen Kokille erlaubt eine präzisere Einstellung der Abkühlgeschwindigkeit insbesondere über die Wahl der radial zur Längsachse des Walzenkörpers gemessenen Dicke der Kokille, der spezifischen oder der absoluten Wärmekapazität, der thermischen Leitfähigkeit oder der Masse der Kokille oder einer geeigneten Kombination solcher Einstellparameter seitens der Kokille. Im Vergleich mit dem konventionellen Schalenhartguss, der üblicherweise ebenfalls im Kokillengussverfahren erfolgt, allerdings mit weiß erstarrender Umfangsrandzone, kann die Abkühlgeschwindigkeit beispielsweise mittels einer einzigen oder bevorzugt einer Kombination von mehreren der folgenden Maßnahmen gesteuert werden: geringere Kokillendicke, Verwendung einer Kokille aus einem Werkstoff geringerer Wärmekapazität, Verwendung einer Kokille geringerer thermischer Leitfähigkeit, geringere Kokillenmasse, jeweils im Vergleich mit einer Kokille zum Gießen eines Walzenkörpers gleicher Geometrie und gleichem Materials im konventionellen Schalenhartguss.According to the invention, the thermal surface treatment is carried out so that the peripheral edge zone forming casting material, cast iron with nodular graphite or nodular graphite, with nodular graphite being preferred, is converted into fine or very fine-grained perlite with vermicular or nodular graphite or into an interstage structure with spheroidal graphite or vermicular graphite. More specifically, the cast iron matrix is converted into said perlite or interstage structure, and the free graphite already precipitated by the casting as a stable phase is retained. Further, the melt is not poured into sand, but against mold to control the cooling rate to be able to. Chill casting can be static or instead dynamic, ie centrifugal casting. The roll body is expediently poured upright, ie with its longitudinal axis in vertical alignment. The casting against mold allows a more precise adjustment of the cooling rate, in particular via the choice of the thickness of the mold measured radially to the longitudinal axis of the roll body, the specific or the absolute heat capacity, the thermal conductivity or the mass of the mold or a suitable combination of such adjustment parameters by the mold. In comparison with the conventional shell casting, which is also usually done by chill casting, but with white solidifying peripheral edge zone, the cooling rate can be controlled, for example, by a single or, preferably, a combination of several of the following: lower die thickness, use of a die of a lower heat capacity material , Use of a mold of lower thermal conductivity, lower mold mass, in each case in comparison with a mold for casting a roll body of the same geometry and the same material in conventional hard shell casting.
In bevorzugten Ausführungen, wird die Abkühlgeschwindigkeit durch Kühlung an der Kokille nicht nur so klein eingestellt, dass die Schmelze auch in der Umfangsrandzone stabil erstarrt, sondern andererseits so groß, dass wie vorstehend für den bevorzugten Kugelgraphit erläutert der Kugelgraphit in der Umfangsrandzone in Graphitkugeln ausgeschieden wird mit einer maximalen Größe entsprechend der Richtzahl 5, vorzugsweise einer maximalen Größe der Richtzahl 6, nach EN ISO 945. Besonders bevorzugt liegen die Graphitkugeln im Größenbereich zwischen 7 und 8 nach EN ISO 945, also bei der Richtzahl 7/8 vor. Solch eine feine Graphitausscheidung wirkt sich positiv auf die mechanische Festigkeit aus. Die Feinausscheidung des Graphits erhöht auch die Regelmäßigkeit der umgebenden Gusseisenmatrix, was wiederum für die Umwandlung dieses nach dem Guss vorliegenden Grundgefüges in fein- oder feinststreifigen Perlit oder in ein Zwischenstufengefüge von Vorteil ist.In preferred embodiments, the cooling rate is set by cooling the mold not only so small that the melt solidifies stable in the peripheral edge zone, but on the other hand so large that, as explained above for the preferred spheroidal graphite nodular graphite is precipitated in the peripheral edge zone in graphite spheres with a maximum size corresponding to the
Durch die thermische Oberflächenbehandlung wird der Walzengusskörper bis in eine radiale Tiefe von vorteilhafterweise wenigstens 3mm, bevorzugt wenigstens 5mm gehärtet, indem die Gusseisenmatrix bis wenigstens in dieser Einhärttiefe in den fein- oder feinststreifigen Perlit oder das Zwischenstufengefüge umgewandelt wird. Für die Größenklasse von Walzenkörpern, auf die es die Erfindung in erster Linie absieht, ist eine Einhärttiefe von 7mm optimal. Eine Einhärttiefe über 10mm soll zwar nicht ausgeschlossen werden, große Einhärttiefen erzeugen jedoch bei Temperaturwechsel Materialspannungen verbunden mit der Gefahr, dass die gehärtete Schicht, die Umfangsrandzone, abplatzt. Als Verfahren der thermischen Oberflächenbehandlung kommen insbesondere Flammhärten und Induktionshärten in Frage, wobei Induktionshärten der Vorzug gegeben wird, da Flammhärten auf den unteren Bereich der Einhärttiefe, im Allgemeinen noch unterhalb 3mm, begrenzt ist. Flammhärten kommt daher in erster Linie für Walzenkörper mit kleinen Durchmessern von bis zu 600 mm in Betracht, wobei allerdings dem Induktionshärten auch hier der Vorzug gegeben wird. Die Umfangsrandzone wird in Abhängigkeit von der gewünschten Oberflächenhärte und Einhärttiefe kurzzeitig in den austenitischen Bereich, vorzugsweise auf wenigstens 880°C und besonders bevorzugt auf etwa 950°C erwärmt. Das erwärmte Material wird durch eine Oberflächenkühlung, vorzugsweise mittels einer Wasserabschreckung, in kurzer Zeit auf unter 100°C, vorzugsweise unter 50°C, abgekühlt, so dass die isotherme Umwandlung in den fein- oder feinststreifigen Perlit stattfindet. Soll das Gusseisen der Umfangsrandzone in ein Zwischenstufengefüge umgewandelt werden, wird eine höhere Abkühlgeschwindigkeit eingestellt, die aber immer noch nicht so groß ist, dass nennenswert eine martensitische Umwandlung stattfindet. Martensit wird wegen der damit verbundenen Rissgefahr im Idealfall gänzlich vermieden. Das Gusseisen der Umfangsrandzone weist in bevorzugten Ausführungen daher eine Martensitstarttemperatur Ms auf, die unter den vorstehend angegebenen Werten, d.h. unter 100°C, vorzugsweise unter 50°C, liegt. Besonders bevorzugt weist der Werkstoff der Umfangsrandzone eine Martensitstarttemperatur Ms auf, die unterhalb Raumtemperatur, d.h. unterhalb 20°C liegt.Due to the thermal surface treatment of the roll body is hardened to a radial depth of advantageously at least 3mm, preferably at least 5mm by the cast iron matrix to at least in this Einhärttiefe in the fine or feinststreifigen perlite or the interstitial structure is converted. For the size class of roll bodies, on which it disregards the invention in the first place, a Einhärttiefe of 7mm is optimal. Although a hardening depth of more than 10 mm should not be ruled out, large hardening depths produce material tensions when the temperature changes, with the risk that the hardened layer, the peripheral edge zone, will flake off. Flame hardening and induction hardening are particularly suitable as methods of thermal surface treatment, preference being given to induction hardening, since flame hardening is limited to the lower part of the hardening depth, generally even below 3 mm. Flame hardening is therefore primarily for roll body with small diameters of up to 600 mm into consideration, although the induction hardening is also given preference here. Depending on the desired surface hardness and hardening depth, the peripheral edge zone is briefly heated to the austenitic region, preferably to at least 880 ° C. and particularly preferably to about 950 ° C. The heated material is cooled by a surface cooling, preferably by means of a water quenching, in a short time to below 100 ° C, preferably below 50 ° C, so that the isothermal conversion takes place in the fine or feinststreifigen perlite. If the cast iron of the peripheral edge zone to be converted into an intermediate structure, a higher cooling rate is set, but still not so large that a significant martensitic transformation takes place. Martensite is ideally avoided because of the associated risk of cracking. The cast iron of the peripheral edge zone therefore has, in preferred embodiments, a martensite start temperature M s which is below the values given above, ie below 100 ° C., preferably below 50 ° C. Particularly preferably, the material of the peripheral edge zone has a martensite start temperature M s which is below room temperature, ie below 20 ° C.
Der oberflächengehärtete Walzenkörper wird vorteilhafterweise angelassen, um Spannungen abzubauen. Die Anlasstemperatur liegt über der Temperatur, die der Walzenkörper im späteren Betrieb höchstens erreicht, vorteilhafterweise über 30°C, bevorzugt wird eine Anlasstemperatur aus dem Bereich von 300 bis 350 °C. Auch nach solch einem Anlassen weist der Walzenkörper in der Umfangsrandzone das fein- oder feinststreifg perlitische Gefüge mit Kugel- oder Vermikulargraphit oder das Zwischenstufengefüge mit Kugel- oder Vermikulargraphit auf.The surface hardened roll body is advantageously tempered to relieve stresses. The tempering temperature is above the temperature that reaches the roller body in later operation at the most, advantageously above 30 ° C, preferably a tempering temperature in the range of 300 to 350 ° C. Even after such an annealing, the roll body in the peripheral edge zone on the fine or feinststreifg pearlitic structure with spherical or vermicular graphite or the interstage structure with spherical or vermicular graphite.
Die Eisenbasislegierung hat einen Kohlenstoffgehalt von vorzugsweise wenigstens 3%, vorzugsweise höchstens 4%. Der Siliziumgehalt beträgt vorzugsweise wenigstens 1.7 und vorzugsweise höchstens 2.4%, wobei auch dies wie stets Masse-% sind. Der Sättigungsgrad Sc der Legierung liegt vorzugsweise im Bereich von 0.97 bis 1.03, bevorzugt ist er geringfügig kleiner als 1.0, so dass die Schmelze leicht untereutektisch ist. Ein bevorzugter Legierungspartner ist Kupfer, als Perlitbildner, und mit einem Anteil von vorzugsweise wenigstens 0.5 und bevorzugt höchstens 1.3%. Ein besonders bevorzugter Legierungspartner ist auch Nickel, das in einem Anteil von vorzugsweise über 0.3%, noch bevorzugter über 0.5%, und vorzugsweise höchstens 1.5% zulegiert ist. Nickel erhöht die Zähigkeit und macht den Werkstoff korrosionsträger. Von besonderem Wert ist Nickel allerdings zur Verhinderung einer Martensitumwandlung beim Härten. Enthält die Eisenbasisiegierung sowohl Silizium als auch Nickel, ist es vorteilhaft, wenn der Siliziumgehalt mit steigendem Nickelgehalt und der Nickelgehalt mit steigendem Siliziumgehalt abnehmen. Bevorzugt wird ein Siliziumanteil aus der unteren Hälfte des für Silizium angegebenen Bereichs und ein Nickelanteil aus dem mittleren Teil des für Nickel angegebenen Bereichs. Eine besonders bevorzugte Eisenlegierung enthält als Legierungspartner sowohl Ni als auch Cu mit bevorzugt wenigstens den hierfür jeweils angegebenen Mindestanteilen. Optionale Legiertzngspartner sind auch Mangan und Zinn, Mangan vorzugsweise aus dem Bereich von 0.3 bis 0.45%, Zinn bevorzugt aus dem Bereich von 0.005 bis 0.015%. Gegenüber den vorstehend genannten anderen Legierungselementen tritt die Bedeutung von Mangan und Zinn aber zurück. Eine bevorzugte Eisenbasislegierung enthält dementsprechend C, Si, Ni und Cu innerhalb der bevorzugten Anteilsgrenzen, gegebenenfalls Mn und Sn, sowie unvermeidbare Restanteile P und S sowie den Rest Fe. Etwaige Anteile von Phosphor und Schwefel liegen vorteilhafterweise jeweils deutlich unter 0.1%, bevorzugter noch deutlich unter 0.05%.The iron-base alloy has a carbon content of preferably at least 3%, preferably at most 4%. The silicon content is preferably at least 1.7 and preferably at most 2.4%, whereby these are also always% by mass. The degree of saturation Sc of the alloy is preferably in the range of 0.97 to 1.03, preferably it is slightly smaller than 1.0, so that the melt is slightly hypoeutectic. A preferred alloying partner is copper, as a perlite former, and in a proportion of preferably at least 0.5 and preferably at most 1.3%. A particularly preferred alloying partner is also nickel, which is alloyed in a proportion of preferably more than 0.3%, more preferably more than 0.5%, and preferably at most 1.5%. Nickel increases the toughness and makes the material corrosion-resistant. However, nickel is of particular value for preventing martensite transformation during curing. If the iron base alloy contains both silicon and nickel, it is advantageous if the silicon content decreases with increasing nickel content and the nickel content decreases with increasing silicon content. Preference is given to a silicon content from the lower half of the range specified for silicon and a nickel content from the middle part of the range specified for nickel. A particularly preferred iron alloy contains as alloying partners both Ni and Cu with preferably at least the minimum proportions indicated for each. Optional alloying partners are also manganese and tin, manganese preferably in the range of 0.3 to 0.45%, tin preferably in the range of 0.005 to 0.015%. Compared to the other alloying elements mentioned above, however, the meaning of manganese and tin is reversed. Accordingly, a preferred iron-based alloy contains C, Si, Ni and Cu within the preferred limits of the proportions, optionally Mn and Sn, as well as unavoidable residual P and S and the remainder Fe. Any proportions of phosphorus and sulfur are advantageously each well below 0.1%, more preferably still well below 0.05%.
Vorteilhafte Merkmale werden ferner in den Unteransprüchen und deren Kombinationen offenbart.Advantageous features are further disclosed in the subclaims and their combinations.
Nachfolgend wird ein Ausführungsbeispiel der Erfindung anhand von Figuren erläutert. An den Figuren offenbar werdende Merkmale bilden je einzeln und in jeder Merkmalskombination die Gegenstände der Ansprüche und auch die vorstehend beschriebenen Ausgestaltungen vorteilhaft weiter. Es zeigen:
Figur 1- eine Walze mit einem erfindungsgemäßen Walzenkörper;
- Figur 2
- den Querschnitt
A-A der Figur 1 ; Figur 3- Details zum Mikrogefüge des Walzenkörpers;
Figur 4- den Walzenkörper während einer thermischen Oberflächenbehandlung;
Figur 5- ein Schliffbild des Grundgefüges des Walzenkörpers;
Figur 6- ein Schliffbild des Gefüges einer mittels der thermischen Oberflächenbehandlung gehärteten Umfangsrandzone des Walzenkörpers; und
Figur 7- den Mikrohärteverlauf in der gehärteten Umfangsrandzone.
- FIG. 1
- a roller with a roller body according to the invention;
- FIG. 2
- the cross section AA of
FIG. 1 ; - FIG. 3
- Details of the microstructure of the roll body;
- FIG. 4
- the roll body during a thermal surface treatment;
- FIG. 5
- a microsection of the basic structure of the roll body;
- FIG. 6
- a micrograph of the structure of a cured by means of the thermal surface treatment peripheral edge zone of the roller body; and
- FIG. 7
- the microhardness curve in the hardened peripheral edge zone.
Der Erstarrungsprozess wird so gesteuert, dass die Schmelze nicht nur in einer die Rotationsachse R umgebenden inneren Zone 5 stabil erstarrt, sondern auch in einer die innere Zone 5 umschließenden Umfangsrandzone 6, die den äußeren Umfang des Walzenkörpers bildet. Der Walzenkörper 1 erstarrt somit über seinen gesamten Querschnitt stabil und nicht weiß. Der Kohlenstoff wird bei der stabilen Erstarrung in Form von Kugelgraphit ausgeschieden. Der durch den Gießprozess unmittelbar erhaltene Walzenkörper 1 weist somit überall ein Sphärogussgefüge auf. Aufgrund der mittels der Kokille gezielt eingestellten Abkühlgeschwindigkeit scheidet sich der Graphit in der Umfangsrandzone 1 jedoch feiner als in der inneren Zone 5 aus. Die Graphit-Sphärolite SG (Sphäro-Graphitteilchen) der Umfangsrandzone 6 haben eine Größe aus dem Bereich der Richtzahlen von 5 bis 8, also eine größte Abmessung von höchstens 0.12 mm. Bevorzugter wird die Abkühlgeschwindigkeit so eingestellt, dass die Graphitteilchen SG der Umfangsrandzone 6 eine Größe aus dem Bereich der Richtzahlen von 7 (0.022 µm) bis 8 nach EN ISO 945 haben, also eine größte Abmessung von höchstens 0.03 mm. Die Gusseisenmatrix ist auch in der Umfangsrandzone 6 perlitisch mit allenfalls einem geringen Ferritanteil. Der Perlitanteil beträgt wenigstens 90%, bevorzugter wenigstens 95%, und der Ferritanteil höchstens 10%, bevorzugter höchstens 5%. Soweit eine Karbidbildung nicht verhindert werden kann, liegt der Karbidanteil nicht nur in der inneren Zone 5, sondern auch in der mit höherer Abkühlgeschwindigkeit erstarrten Umfangsrandzone 6 unter 5%, bevorzugter unter 3%.The solidification process is controlled so that the melt solidly solidifies not only in an
Der Walzenkörper 1 wird in seiner bereits durch den Guss erhaltenen, höherfesten Umfangsrandzone 6 in einem nachfolgenden Härtungsprozess verschleißfest gemacht. Vor oder nach dem Härten werden die peripheren Temperierkanäle 4 eingearbeitet, vorzugsweise gebohrt. Als Umfangsrandzone 6 wird diejenige Ringzone des Walzenkörpers 1 verstanden, die nach dem Härten die für die jeweilige Anwendung geforderte Härte überall aufweist, sich also vom äußeren Umfang bis in die Einhärttiefe erstreckt. Falls die Umfangsrandzone 6 des gehärteten Walzenkörpers 1 sich radial einwärts bis zu oder sogar über die Temperierkanäle 4 erstreckt, werden diese zweckmäßigerweise vor dem Härten eingearbeitet. Andernfalls können die Temperierkanäle 4 ebensogut erst nach dem Härten eingearbeitet werden.The
Der Härtungsprozess wird so durchgeführt, dass das unmittelbar aus dem Guss erhaltene Grundgefüge der Umfangsrandzone 6 in feinstreifigen oder noch vorteilhafter, in feinststreifigen Perlit umgewandelt wird. Die Graphitsphärolite SG werden hierdurch nicht oder zumindest nicht in einer für die Erfindung maßgeblichen Weise verändert. Alternativ zu der Umwandlung in fein- oder feinststreifigen Perlit, d.h. in Sorbit oder Troostit, kann der Härtungsprozess auch so gestaltet werden, dass sich die Gusseisenmatrix innerhalb der Umfangsrandzone 6 in ein Zwischenstufengefüge umwandelt, vorzugsweise in ADI (austempered ductile iron). In beiden Varianten wird der Walzenkörper 1 in der Umfangsrandzone 6 gleichmäßig auf eine Temperatur im austenitischen Bereich erwärmt, beispielsweise auf 950°C, und anschließend abgeschreckt, wobei die Abschreckgeschwindigkeit für die Bildung eines Zwischenstufengefüges höher als für die Umwandlung in den feinen Perlit eingestellt wird, aber immer noch nicht so groß ist, dass eine Martensitumwandlung stattfinden kann. Das Zwischenstufengefüge ähnelt dem Bainit, bevorzugt dem unteren Bainit, ist aber kein Bainit, da es keine oder für die angestrebte Festigkeit nur vernachlässigbar wenig Karbide enthält. Auch für das Zwischenstufengefüge gilt, dass der Karbidanteil vorteilhafterweise weniger als 5%, vorzugsweise höchstens 3% beträgt. Im Sinne der Erfindung wäre es ideal, wenn weder das feinperlitische Gefüge noch das alternative Zwischenstufengefüge Karbide enthalten würden.The hardening process is carried out in such a way that the basic structure of the
Die
In
Der gehärtete Walzenkörper 1 wird angelassen, vorteilhafterweise auf eine Anlasstemperatur zwischen 300 und 350°C.The
In der nachfolgenden Tabelle wird eine für das Gießen des Walzenkörpers 1 besonders bevorzugte Eisenbasislegierung in der letzten Tabellenspalte spezifiziert. Die zweite und dritte Spalte enthalten bevorzugte Bereiche für den jeweiligen Legierungspartner, wobei die engeren Bereiche innerhalb des jeweils weiteren Bereichs für das gleiche Legierungselement besonders bevorzugt werden. Für den jeweiligen Legierungspartner wird dann wiederum der in der letzten Spalte angegebene Anteil am stärksten bevorzugt. Die Eisenbasislegierung enthält in bevorzugter Ausführung zumindest Kohlenstoff, Silicium, Kupfer und Nickel innerhalb der jeweils spezifizierten Anteilsbereiche. Kupfer als Perlitbildner und Nickel zur Verhinderung einer Martensitumwandlung kommen vorzugsweise in Kombination zum Einsatz. Fe macht den Rest der jeweiligen Legierung aus.
Masse-%
Masse-%
Masse-%
Dimensions-%
Dimensions-%
Dimensions-%
Die Eisenbasisschmelze der Zusammensetzung der letzten Spalte weist einen Sättigungsgrad Sc von 0.99 bis 1.00 auf. Bevorzugt werden Eisenbasislegierungen mit einem Sättigungsgrad Sc aus dem Bereich von 0.97 bis 1.03, wobei aus diesem Bereich von Legierungen naheutelctischer Zusammensetzung solche mit einem Sättigungsgrad Sc aus der unteren Hälfte des angegeben Bereichs bevorzugt werden.The iron base melt of the composition of the last column has a saturation degree Sc of 0.99 to 1.00. Preference is given to iron-base alloys having a degree of saturation Sc in the range from 0.97 to 1.03, from which range of alloys of near-tectic composition those having a degree of saturation Sc from the lower half of the stated range are preferred.
An einer nach dem erfindungsgemäßen Verfahren gegossenen und gehärteten Probe mit fein- und feinststreifigem Perlit mit Kugelgraphit, an der auch die Schliffbilder der
- (i) 0.2%-Dehngrenze Rp, 0.2 > 400 N/mm2;
- (ii) Zugfestigkeit Rm > 650 N/mm2;
- (iii) Bruchdehnung A > 3-4%.
- (iv) Härte > 400 HV
- (i) 0.2% proof stress R p , 0.2> 400 N / mm 2 ;
- (ii) tensile strength R m > 650 N / mm 2 ;
- (iii) Elongation at break A> 3-4%.
- (iv) hardness> 400 HV
Der Walzenkörper 1 des Ausführungsbeispiels ist in einem Sphärogussgefüge erstarrt. In alternativen Ausführungen kann der eingelagerte freie Graphit in der inneren Zone 5 und auch in der Umfangsrandzone 6 im Wesentlichen in Form von Vermikulargraphit oder auch in Form von Kugelgraphit und Vermikulargraphit ausgeschieden sein. Der Ausscheidung von Kugelgraphit wird gegenüber der Ausscheidung von Vermikulargraphit allerdings der Vorzug gegeben. In Ausführungen, in denen der freie Graphit als Kugelgraphit und auch als Vermikulargraphit vorliegt, ist es vorteilhaft, wenn der Kugelgraphit den überwiegenden Teil des freien Graphits ausmacht.The
Claims (16)
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Also Published As
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US20100179039A1 (en) | 2010-07-15 |
DE102009004562A1 (en) | 2010-07-15 |
DE102009004562B4 (en) | 2015-06-03 |
EP2213790B1 (en) | 2013-07-03 |
US8684895B2 (en) | 2014-04-01 |
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