Iron-based roller blank, preparation method and application thereof

Abstract

The present invention discloses an iron-based roller blank and its preparation method and application, and relates to the field of surface treatment technology. It comprises a substrate and a corrosion-resistant coating on the surface of the substrate. The material of the substrate is any one of low-carbon steel and 45# steel, and the material of the corrosion-resistant coating is stainless steel. By spraying the stainless steel material on the surface of the substrate, not only the corrosion resistance of the roller blank substrate is improved, but also the possibility of cracks and gaps in the roller blank during use is reduced; at the same time, the stainless steel coating has good compatibility with the substrate. In actual use, different coatings will be sprayed on the surface of different roller structures, and the materials of stainless steel and the substrate are similar. Therefore, when other coatings are sprayed on the surface of the iron-based roller blank again, the coating and the corrosion-resistant coating will not separate or peel off.

Description

Technical Field

[0001] The present invention relates to the technical field of surface treatment, and in particular to an iron-based roller blank and a preparation method and application thereof. Background Art

[0002] Roller structures are very common in the steel, printing, and machinery industries, such as hot-rolled steel rolls, straightening rolls, table rolls, pinch rolls, anilox rolls, and coating rolls. Iron-based steel materials, such as low-carbon steel, are often used as the base of roller structures because of their high crack resistance, high strength, high toughness, good machinability, and ease of forging, welding, and cutting, as well as their low cost.

[0003] However, because low-carbon steel rusts more easily than other steels, it can cause severe corrosion, cracking, fissures, and voids. In harsh environments, these problems can exacerbate product breakage and failure, leading to equipment damage, production line downtime, and component scrapping.

[0004] In view of this, the present invention is proposed. Summary of the Invention

[0005] The purpose of the present invention is to provide an iron-based roller blank and a preparation method and application thereof.

[0006] The present invention is achieved in that:

[0007] In a first aspect, the present invention provides an iron-based roller blank, comprising a substrate and a corrosion-resistant coating on the surface of the substrate, wherein the substrate is made of any one of low carbon steel and 45# steel, and the corrosion-resistant coating is made of stainless steel.

[0008] In an optional embodiment, the corrosion-resistant coating has a thickness of 10 to 70 μm.

[0009] Preferably, the stainless steel includes any one of 316L stainless steel and 304 stainless steel.

[0010] In an optional embodiment, the base is hollow cylindrical, and preferably, the length of the base is 3 to 5 meters.

[0011] In a second aspect, the present invention provides a method for preparing an iron-based roller blank as described in any of the aforementioned embodiments, comprising spraying a corrosion-resistant coating on the surface of the substrate using a supersonic flame spraying technique.

[0012] In an optional embodiment, the parameters of the supersonic flame spraying technology include: hydrogen flow rate 9-12 L / h; nitrogen flow rate 10-30 L / h; air flow rate 50-80 L / h; spraying distance 200-240 mm; and powder feeding rate 5-10 g / min.

[0013] Preferably, the parameters of the supersonic flame spraying technology include: hydrogen flow rate 9-11 L / h; nitrogen flow rate 10-20 L / h; air flow rate 50-70 L / h; spraying distance 200-220 mm; and powder feeding rate 6-9 g / min.

[0014] In an optional embodiment, the substrate is pretreated before the supersonic flame spraying, and the pretreatment includes cleaning, sandblasting and preheating.

[0015] In an optional embodiment, the preheating includes preheating the substrate using a supersonic velocity flame spraying technique.

[0016] Preferably, the parameters of the supersonic flame spraying during preheating include: hydrogen flow rate of 5 to 9 L / h; nitrogen flow rate of 10 to 30 L / h; air flow rate of 60 to 70 L / h; and spraying distance of 220 to 240 mm.

[0017] Preferably, the preheating time is 20 to 30 minutes.

[0018] In an optional embodiment, the sandblasting material includes any one of zirconium corundum and brown corundum.

[0019] Preferably, the pressure of the sandblasting gun is 0.7-1.0 MPa.

[0020] In an alternative embodiment, cleaning comprises using ultrasonic cleaning.

[0021] Preferably, the cleaning solution comprises alcohol or gasoline.

[0022] In a third aspect, the present invention provides an application of an iron-based roller blank according to any one of the aforementioned embodiments or an iron-based roller blank prepared by the preparation method according to any one of the aforementioned embodiments in the fields of steel, printing or machinery.

[0023] The present invention has the following beneficial effects:

[0024] The present invention provides an iron-based roller blank, a preparation method thereof, and an application thereof. By spraying stainless steel material on the surface of the base, not only the corrosion resistance of the roller blank base is improved, but also the possibility of cracks and gaps in the roller blank during use is reduced; at the same time, the stainless steel coating has good compatibility with the base. In actual use, different coatings are sprayed on the surfaces of different roller structures, and the materials of stainless steel and the base are similar. Therefore, when other coatings are sprayed on the surface of the iron-based roller blank again, the coating and the corrosion-resistant coating will not separate or peel off. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. It should be understood that the following drawings only illustrate certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without paying any creative work.

[0026] Figure 1 This is a cross-sectional SEM image of the substrate and corrosion-resistant coating of the iron-based roller blank provided in Example 1 of the present invention;

[0027] Figure 2 This is a graph showing the results of a neutral salt spray corrosion resistance test on an iron-based roller blank provided in Example 1 of the present invention;

[0028] Figure 3 This is a graph showing the results of a neutral salt spray corrosion resistance test on the iron-based roller blank substrate provided by the present invention;

[0029] Figure 4 This is a cross-sectional SEM image of the substrate and corrosion-resistant coating of the iron-based roller blank provided in Example 1 of the present invention after the neutral salt spray corrosion resistance test;

[0030] Figure 5 This is a cross-sectional SEM image of the substrate and corrosion-resistant coating of the iron-based roller blank provided in Example 2 of the present invention after the neutral salt spray corrosion resistance test;

[0031] Figure 6 This is a cross-sectional SEM image of the substrate and corrosion-resistant coating of the iron-based roller blank provided in Example 3 of the present invention after the neutral salt spray corrosion resistance test. DETAILED DESCRIPTION

[0032] To make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention are described clearly and completely below. Where specific conditions are not specified in the embodiments, conventional conditions or conditions recommended by the manufacturer are used. Where the manufacturer of the reagents or instruments is not specified, all are conventional products that can be purchased commercially.

[0033] Roller structures are typically constructed from steel. However, steel, especially mild steel, is subject to corrosion over time, and this is particularly true for mild steel. Mild steel is more susceptible to rust than other steels, leading to severe corrosion, cracking, fissures, and voids. In harsh environments, these conditions can exacerbate product breakage and failure, leading to equipment damage, production line downtime, and component failure. Therefore, the inventors propose the following solution.

[0034] In a first aspect, the present invention provides an iron-based roller blank, comprising a substrate and a corrosion-resistant coating on the surface of the substrate, wherein the substrate is made of any one of low carbon steel and 45# steel, and the corrosion-resistant coating is made of stainless steel.

[0035] By spraying stainless steel material on the surface of the substrate, not only the corrosion resistance of the roller substrate is improved, but also the possibility of cracks and gaps in the roller during use is reduced; at the same time, the stainless steel coating has good compatibility with the substrate. In actual use, different coatings will be sprayed on the surfaces of different roller structures, and the materials of stainless steel and the substrate are similar. Therefore, when other coatings are sprayed on the surface of the iron-based roller again, it will not cause separation or peeling of the coating and the corrosion-resistant coating.

[0036] In an optional embodiment, the thickness of the corrosion-resistant coating is 10-70 μm. For example, the thickness of the corrosion-resistant coating can be 10 μm, 15 μm, 20 μm, 25 μm, 30 μm, 35 μm, 40 μm, 45 μm, 50 μm, 55 μm, 60 μm, 65 μm or 70 μm.

[0037] Preferably, the stainless steel includes any one of 316L stainless steel and 304 stainless steel.

[0038] In an optional embodiment, in order to reduce the weight of the roller blank, the base is hollow cylindrical. Preferably, the length of the base is 3 to 5 meters.

[0039] The stainless steel material and low carbon steel material mentioned in the present invention can be conventional materials currently available on the market.

[0040] In a second aspect, the present invention provides a method for preparing an iron-based roller blank as described in any of the aforementioned embodiments, comprising spraying a corrosion-resistant coating on the surface of the substrate using a supersonic flame spraying technique.

[0041] Supersonic Oxygen Flame Spraying utilizes fuel gas or hydrogen and high-pressure oxygen to produce a high-temperature, high-velocity flame stream in a combustion chamber or through a special nozzle. Powder is fed axially into the flame stream, heating it to a molten or semi-molten state and accelerating it, resulting in a high-strength, dense, and high-quality coating.

[0042] In an optional embodiment, the parameters of the supersonic flame spraying technology include: hydrogen flow rate 9-12 L / h; nitrogen flow rate 10-30 L / h; air flow rate 50-80 L / h; spraying distance 200-240 mm; and powder feeding rate 5-10 g / min.

[0043] Preferably, the parameters of the supersonic flame spraying technology include: hydrogen flow rate 9-11 L / h; nitrogen flow rate 10-20 L / h; air flow rate 50-70 L / h; spraying distance 200-220 mm; and powder feeding rate 6-9 g / min.

[0044] By controlling the parameters of supersonic flame spraying within the above range, the stainless steel material can be better melted, the bond between the corrosion-resistant coating and the substrate is tighter, the coating structure is dense and free of holes, and the corrosion resistance of the substrate is improved.

[0045] In an optional embodiment, in order to improve the bonding ability between the corrosion-resistant coating and the substrate, the substrate is pretreated before the HVOF spraying, wherein the pretreatment includes cleaning, sandblasting, and preheating.

[0046] In an optional embodiment, the preheating includes preheating the substrate using a supersonic velocity flame spraying technique.

[0047] Preferably, the parameters of the supersonic flame spraying during preheating include: hydrogen flow rate of 5 to 9 L / h; nitrogen flow rate of 10 to 30 L / h; air flow rate of 60 to 70 L / h; and spraying distance of 220 to 240 mm.

[0048] Preferably, the preheating time is 20 to 30 minutes.

[0049] In an optional embodiment, the sandblasting material includes any one of zirconium corundum and brown corundum.

[0050] Preferably, the pressure of the sandblasting gun is 0.7-1.0 MPa.

[0051] In an alternative embodiment, cleaning comprises using ultrasonic cleaning.

[0052] Preferably, the cleaning solution comprises alcohol or gasoline.

[0053] In a third aspect, the present invention provides an application of an iron-based roller blank according to any one of the aforementioned embodiments or an iron-based roller blank prepared by the preparation method according to any one of the aforementioned embodiments in the fields of steel, printing or machinery.

[0054] The features and performance of the present invention are further described in detail below with reference to the embodiments.

[0055] Example 1

[0056] This embodiment provides an iron-based roller blank, comprising a Q215 low-carbon steel substrate and a 316L stainless steel corrosion-resistant coating, wherein the corrosion-resistant coating is 50 μm thick, the substrate is a hollow cylinder, and the length of the substrate is 4.5 m.

[0057] This embodiment also provides a method for preparing an iron-based roller blank, comprising the following steps:

[0058] S1. Substrate cleaning and sandblasting

[0059] The Q215 low carbon steel was immersed in an alcohol solution for ultrasonic cleaning. After cleaning, zirconium corundum sand was sprayed on the surface of the substrate with a sandblasting pressure of 0.7 MPa.

[0060] S2. Substrate preheating and spraying corrosion resistant coating

[0061] The sandblasted substrate was preheated using a supersonic flame spray gun, with a hydrogen flow rate of 7 L / h, a nitrogen flow rate of 20 L / h, and an air flow rate of 65 L / h. The spraying distance was 230 mm, and the preheating time was 25 min.

[0062] After preheating, the supersonic flame spray gun parameters were adjusted to hydrogen flow rate 9 L / h; nitrogen flow rate 10 L / h; air flow rate 50 L / h; spraying distance 200 mm; and powder feed rate 6 g / min.

[0063] The iron-based roller blank prepared in this embodiment was placed under a scanning electron microscope for observation, and the following Figure 1 The results shown by Figure 1 It can be seen that the corrosion-resistant coating has good compatibility with the substrate, and the corrosion-resistant coating has a dense structure without cracks.

[0064] Example 2

[0065] This embodiment provides an iron-based roller blank, comprising a Q215 low-carbon steel substrate and a 316L stainless steel corrosion-resistant coating, wherein the corrosion-resistant coating is 50 μm thick, the substrate is a hollow cylinder, and the length of the substrate is 4.5 m.

[0066] This embodiment also provides a method for preparing an iron-based roller blank, comprising the following steps:

[0067] S1. Substrate cleaning and sandblasting

[0068] The Q215 low carbon steel was immersed in an alcohol solution for ultrasonic cleaning. After cleaning, zirconium corundum sand was sprayed on the surface of the substrate with a sandblasting pressure of 0.7 MPa.

[0069] S2. Substrate preheating and spraying corrosion resistant coating

[0070] The sandblasted substrate was preheated using a supersonic flame spray gun, with a hydrogen flow rate of 7 L / h, a nitrogen flow rate of 20 L / h, and an air flow rate of 65 L / h. The spraying distance was 230 mm, and the preheating time was 25 min.

[0071] After preheating, the supersonic flame spray gun parameters were adjusted to hydrogen flow rate 11 L / h; nitrogen flow rate 20 L / h; air flow rate 70 L / h; spraying distance 220 mm; and powder feed rate 9 g / min.

[0072] Example 3

[0073] This embodiment provides an iron-based roller blank, comprising a Q215 low-carbon steel substrate and a 316L stainless steel corrosion-resistant coating, wherein the corrosion-resistant coating is 70 μm thick, the substrate is a hollow cylinder, and the length of the substrate is 4.5 m.

[0074] This embodiment also provides a method for preparing an iron-based roller blank, comprising the following steps:

[0075] S1. Substrate cleaning and sandblasting

[0076] The Q215 low carbon steel was immersed in an alcohol solution for ultrasonic cleaning. After cleaning, zirconium corundum sand was sprayed on the surface of the substrate with a sandblasting pressure of 1.0 MPa.

[0077] S2. Substrate preheating and spraying corrosion resistant coating

[0078] The sandblasted substrate was preheated using a supersonic flame spray gun, with a hydrogen flow rate of 7 L / h, a nitrogen flow rate of 20 L / h, and an air flow rate of 65 L / h. The spraying distance was 230 mm, and the preheating time was 25 min.

[0079] After preheating, the supersonic flame spray gun parameters were adjusted to hydrogen flow rate 10 L / h; nitrogen flow rate 15 L / h; air flow rate 60 L / h; spraying distance 210 mm; and powder feed rate 8 g / min.

[0080] Comparative Example 1

[0081] This comparative example provides an iron-based roller blank, the structure and preparation method of which are the same as those of Example 1, with the only difference being that the spraying distance is 260 mm.

[0082] Comparative Example 2

[0083] This comparative example provides an iron-based roller blank, the structure and preparation method of which are the same as those of Example 1, with the only difference being that the sandblasting pressure is 0.1 MPa.

[0084] Comparative Example 3

[0085] This comparative example provides an iron-based roller blank, the structure and preparation method of which are the same as those of Example 1, with the only difference being: hydrogen flow rate: 15 L / h.

[0086] Comparative Example 4

[0087] This comparative example provides an iron-based roller blank, the structure and preparation method of which are the same as those of Example 1, with the only difference being that the spraying material is Cr2O3 powder.

[0088] Comparative Example 5

[0089] This comparative example provides an iron-based roller blank, the structure and preparation method of which are the same as those of Example 1, with the only difference being that the spraying material is Al2O3 powder.

[0090] Test Example 1

[0091] The ASTM C633 method was used to test the bonding between the surface corrosion-resistant layer and the substrate of the iron-based roller blanks prepared in Examples 1 to 3 and Comparative Examples 1 to 5, and the results shown in Table 1 were obtained.

[0092] Table 1 Coating bonding strength of iron-based roller blanks

[0093] Bonding strength MPa Example 1 92 Example 2 89 Example 3 90 Comparative Example 1 67 Comparative Example 2 58 Comparative Example 3 65 Comparative Example 4 21 Comparative Example 5 23

[0094] As can be seen from Table 1, the iron-based roller body provided by the embodiment of the present invention has a corrosion-resistant coating whose material is closer to the substrate. Therefore, when the material of the corrosion-resistant coating is conventionally prepared, the iron-based roller body material has a stronger bonding ability with the corrosion-resistant coating. However, the Al2O3 coating and the Cr2O3 coating have a higher hardness and poor compatibility with the iron-based roller body material. Therefore, it is impossible to obtain an interface bonding with better performance. It is necessary to select other suitable materials to cooperate with the Al2O3 coating and the Cr2O3 coating to obtain an interface bonding with better performance, which increases the difficulty of preparing the material of the corrosion-resistant coating.

[0095] Test Example 2

[0096] The iron-based roller blank with stainless steel coating prepared in Example 1 and the iron-based roller blank prepared in step S1 of Example 1 were subjected to neutral salt spray corrosion test, and the following results were obtained: Figure 2 and Figure 3 Results shown.

[0097] Figure 2 In the embodiment 1, the iron-based roller blank with stainless steel coating was smooth after 240 hours of neutral salt spray corrosion, with no obvious corrosion marks. Figure 3 In the embodiment 1, the iron-based roller blank in step S1 was subjected to the same corrosion test, but obvious corrosion occurred only after 72 hours, indicating that the iron-based roller blank with stainless steel coating prepared in the embodiment of the present invention has stronger corrosion resistance.

[0098] After the iron-based roller blanks with stainless steel coatings prepared in Examples 1 to 3 were subjected to the same neutral salt spray corrosion test for 200 hours, the iron-based roller blanks were placed under a scanning electron microscope for observation, and the following results were obtained: Figures 4-6 The results are shown. Figures 4-6It can be seen that after the corrosion test of the iron-based roller blanks in Examples 1 to 3, the flat part above the picture is the stainless steel coating, and the concave area below the picture is the substrate. It can be found that the iron-based roller blanks provided by the embodiments of the present invention have no signs of corrosion on the surface of the stainless steel coating, while part of the structure on the substrate side has been corroded. However, due to the protective effect of the stainless steel coating on the surface, it still maintains good corrosion resistance.

[0099] The embodiments of the present invention provide an iron-based roller blank, a preparation method thereof, and an application thereof, which have at least the following advantages:

[0100] By spraying stainless steel material on the surface of the substrate, not only the corrosion resistance of the roller substrate is improved, but also the possibility of cracks and gaps in the roller during use is reduced; at the same time, the stainless steel coating has good compatibility with the substrate. In actual use, different coatings will be sprayed on the surfaces of different roller structures, and the materials of stainless steel and the substrate are similar. Therefore, when other coatings are sprayed on the surface of the iron-based roller again, it will not cause separation or peeling of the coating and the corrosion-resistant coating.

[0101] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. An iron-based roller blank, characterized in that: It includes a substrate and a corrosion-resistant coating on the surface of the substrate, wherein the substrate is made of any one of low carbon steel and 45# steel, and the corrosion-resistant coating is made of stainless steel; The stainless steel includes any one of 316L stainless steel and 304 stainless steel; The preparation method of the iron-based roller blank includes spraying a corrosion-resistant coating on the surface of the substrate using a supersonic flame spraying technology. The parameters of the supersonic flame spraying technology include: a hydrogen flow rate of 7 to 12 L / h; a nitrogen flow rate of 10 to 30 L / h; an air flow rate of 50 to 80 L / h; a spraying distance of 200 to 240 mm; and a powder feeding rate of 5 to 10 g / min.

2. The iron-based roller blank according to claim 1, characterized in that: The thickness of the corrosion-resistant coating is 10-70 μm.

3. The iron-based roller blank according to claim 1, characterized in that The base body is in a hollow cylindrical shape.

4. The iron-based roller blank according to claim 1, characterized in that The length of the substrate is 3 to 5 m.

5. The iron-based roller blank according to claim 1, characterized in that: The parameters of the supersonic flame spraying technology include: hydrogen flow rate 9-11 L / h; nitrogen flow rate 10-20 L / h; air flow rate 50-70 L / h; spraying distance 200-220 mm; and powder feeding rate 6-9 g / min.

6. The iron-based roller blank according to claim 1 or 5, characterized in that: Before the supersonic flame spraying, the substrate is pretreated, and the pretreatment includes cleaning, sandblasting and preheating.

7. The iron-based roller blank according to claim 6, characterized in that: The preheating includes preheating the substrate using a supersonic flame spraying technique; The parameters of the supersonic flame spraying during preheating include: hydrogen flow rate 5~9L / h; nitrogen flow rate 10~30L / h; air flow rate 60~70L / h; spraying distance 220~240mm; The preheating time is 20~30min.

8. The iron-based roller blank according to claim 6, characterized in that The material for sandblasting includes any one of zirconium corundum and brown corundum; The pressure of the sandblasting gun is 0.7~1.0MPa.

9. The iron-based roller blank according to claim 6, characterized in that The cleaning comprises ultrasonic cleaning; The cleaning solution includes alcohol or gasoline.

10. Use of the iron-based roller blank according to any one of claims 1 to 9 in the steel or printing fields.

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