Process for making impact-resistant wear-resistant superhard metal matrix composite layers and straightening rolls

Abstract

This invention discloses a process for manufacturing an impact-resistant and wear-resistant ultra-hard metal-based composite layer and a straightening roller, comprising an alloy groove coating layer one, an alloy groove coating layer two, and an alloy working layer; both alloy groove coating layer one and alloy groove coating layer two have sinusoidal structures, are staggered, and have at least one set of intersection nodes between them, and are located inside the alloy working layer. By introducing V and Nb into the original formulation and precisely adjusting the proportions of components such as Co, Ni, Cr, C, B, and Si to meet the requirements, the composite layer retains high hardness and good oxidation resistance, impact resistance, thermal shock resistance, and corrosion resistance at high temperatures, improving the spraying process performance of the alloy coating and increasing the deposition rate.

Description

Technical Field

[0001] This invention relates to the field of straightening rollers, and more particularly to impact-resistant and wear-resistant ultra-hard metal-based composite layers and straightening roller manufacturing processes. Background Technology

[0002] The surface strengthening technologies for roller products are mainly divided into induction heating quenching technology, overlay welding technology, thermal spraying technology, thermal spray welding technology, and laser surface modification technology.

[0003] 1) Induction heating quenching technology

[0004] Induction hardening involves placing a workpiece in an induction coil with sufficient power output. Under the influence of a high-frequency alternating magnetic field, the workpiece surface is rapidly heated above the critical phase transformation temperature of the steel, and then rapidly cooled in a cooling medium to obtain martensite. However, the hardness of the product depends on the material composition; the higher the required hardness, the higher the material cost.

[0005] 2) Overlay welding technology

[0006] Hardfacing is a technique that involves spraying a layer of alloy with special properties such as wear resistance, corrosion resistance, and heat resistance onto the surface of a part. When straightening rolls are repaired using hardfacing, the hardfacing layer achieves a metallurgical bond with the base material, resulting in the thickest surface layer on the straightening roll. Using hardfacing to repair old straightening rolls and manufacture new rolls has become an important measure for reducing costs and improving efficiency. However, it involves high processing heat, significant deformation, large machining allowances, and substantial material loss.

[0007] 3) Electroplating chromium technology

[0008] Electroplating is a process of depositing a layer of metal or alloy onto a solid surface using electrochemical methods. Electroplated layers can improve the corrosion resistance of metal parts in their operating environment, as well as their performance properties such as hardness, wear resistance, conductivity, electromagnetic properties, and heat resistance. Hardness can reach approximately HV900-1000, and it can also decorate the appearance of parts, making them bright and aesthetically pleasing. However, electroplating has a significant environmental impact, and the chromium layer has low bonding strength.

[0009] 4) Thermal spraying technology

[0010] Thermal spraying is a process in which a heat source melts or partially melts the coating material, then high-speed gas disperses and refines the material, which is then impacted onto the substrate surface at high speed to form a coating. Thermal spraying technology results in less deformation of the straightening roller substrate, a shallow heat-affected zone, and a higher coating hardness than welding. Flame spraying also improves wear resistance by 3-4 times compared to arc welding. However, the bond strength between the flame-sprayed coating and the substrate is relatively low, and it cannot withstand alternating loads and impact loads.

[0011] 5) Laser surface modification technology

[0012] The main advantages of laser surface modification are its wide range of processed materials, applicable to non-contact processing of various metallic and non-metallic materials, thermal deformation ≥0.5mm, high processing precision, micro-machining capability, high processing speed and efficiency, and the ability to perform not only drilling and cutting, but also welding and heat treatment; it also offers good controllability, is easy to automate, and can improve product wear resistance and hardness, extending service life. However, it is only suitable for creating micro-metallurgical bonding layers with surface self-fusion on soft substrates, where thermal deformation exceeds the requirements for roller products.

[0013] Supersonic spraying of roller products promises to resolve the contradiction between increasing the hardness of traditional coating materials and the toughness and brittleness of roller products, as well as problems such as decreased compatibility and adhesion between the coating and the substrate, easy cracking of the coating, and easy detachment of the hard phase. Therefore, research on surface coating treatment of materials to obtain good comprehensive mechanical properties is becoming increasingly important. Summary of the Invention

[0014] The technical problem to be solved by this invention is: how to optimize the coating manufacturing process to obtain a high-performance composite coating and a straightening roller using the coating, while improving the bonding ability between the coating and the roller surface.

[0015] To solve the above-mentioned technical problems, the inventors, through practice and summarization, derived the technical solution of this invention, which adopts the following technical solution:

[0016] The impact-resistant and wear-resistant ultra-hard metal-based composite layer includes alloy groove coating layer one, alloy groove coating layer two, and alloy working layer;

[0017] Both alloy trench cladding layer one and alloy trench cladding layer two have sinusoidal structures, are staggered and have at least one set of intersection nodes between them, and are located inside the alloy working layer.

[0018] The components of alloy trench coating one and alloy trench coating two, by weight, include: 13-18 parts Fe, 15-18 parts Cr, 2.5-3.5 parts Co, 3.0-4.0 parts B, 3.0-4.0 parts Si, 0.4-0.8 parts C, 1.0-2.0 parts V, 1.0-2.0 parts Nb, with the balance being Ni and trace impurities, 0.11≤(V+Nb) / (Fe+C+Co)≤0.25, 0.09≤(B+Si+Co) / (Ni+Cr)≤0.19;

[0019] 1) By optimizing the ratio to 0.09≤(B+Si+Co) / (Ni+Cr), the coating achieves high hardness, wear resistance, and heat corrosion resistance. Specifically, Si melts into the alloy matrix, providing solid solution strengthening; Co possesses excellent corrosion resistance, heat resistance, and oxidation resistance; B and Co combine with Ni and / or Cr in the matrix to form hard metal compounds, resulting in dispersed distribution and dispersion strengthening within the alloy. Ensuring precise Co content also promotes the precipitation of dispersed chromium-carbon and boron-chromium hard phases, as well as ductile face-centered cubic solid solutions, and promotes carbide formation at high temperatures. This comprehensive combination enhances the hardness and wear resistance of the cemented carbide, ensures excellent bonding strength, and maintains high hardness, good oxidation resistance, impact resistance, thermal shock resistance, and corrosion resistance at high temperatures. It also improves the coating's spraying process performance and increases the deposition rate.

[0020] 2) Based on the above proportions, the proportions were optimized to meet the condition 0.11≤(V+Nb) / (Fe+C+Co)≤0.25. V and Nb were introduced into the original proportions and precisely adjusted to meet the above proportion range, so that nanoscale carbide second phases were formed inside, which significantly reduced the overheating sensitivity of the coating, refined the grains, and resulted in a fine structure and high strength and toughness after quenching. Since the precise formulation of Co content in the coating has a slight impact on the grain refinement effect, the introduction of V and Nb forms various metal compound phases inside, such as VCo5, ​​VCo3, NbCo2, NbCo5, VNb2, and VNb5. During the solidification process of the alloy, these metal compound phases can act as non-uniform nucleation nuclei, promoting grain nucleation and growth, thereby obtaining fine grains. The metal compound phases can also further refine the grains by hindering grain growth and inhibiting grain boundary movement, and have high strength, high hardness, good corrosion resistance, and high temperature stability. Previous techniques mostly used rare earth elements to achieve the effect of refining grain size.

[0021] The alloy working layer comprises, by weight: 10-13 parts Fe, 8-15 parts Cr, 2.0-3.0 parts B, 2.0-3.0 parts Si, 2.0-4.0 parts C, 32-36 parts W, 1.0-2.0 parts Co, with the balance being Ni and trace impurities. The weights are: 0.13 ≤ (B+Si+Co) / (Ni+Cr) ≤ 0.28, 0.59 ≤ (Co+W) / (Ni+Cr+C) ≤ 0.96.

[0022] The principle of optimizing the proportions to meet the condition 0.13≤(B+Si+Co) / (Ni+Cr)≤0.28 is the same as above. Furthermore, sufficient W is added to the working layer raw material while increasing the C content, relatively reducing the contents of B, Si, Co, and Cr, and meeting the condition 0.59≤(Co+W) / (Ni+Cr+C)≤0.96. This results in the formation of a tungsten-cobalt-carbon compound phase within the coating. This phase, along with B and Co, reacts with Ni and / or Cr in the matrix to form hard metal compounds, resulting in a dispersed distribution within the alloy that provides dispersion strengthening. The combination of B promotes the precipitation of dispersed chromium-carbon and boron-chromium hard phases and promotes the formation of carbides at high temperatures. When combined, it can improve the hardness and wear resistance of cemented carbide, so that it still has high hardness at high temperatures and good oxidation resistance, impact resistance, thermal shock resistance and corrosion resistance. It can also improve the coating process performance of alloy coating and increase the deposition rate, resulting in good toughness and ductility, oxidation and acid corrosion resistance, crack resistance and thermal shock resistance, as well as high wear resistance, high temperature hardness and strength, and resistance to intergranular corrosion and thermal shock.

[0023] Preferably, the alloy trench coating one and alloy trench coating two, by weight, comprise: 13-18 parts Fe, 15-18 parts Cr, 2.5-3.5 parts Co, 3.0-4.0 parts B, 3.0-4.0 parts Si, 0.4-0.8 parts C, 1.0-2.0 parts V, 1.0-2.0 parts Nb, with the balance being Ni and trace impurities, and 0.12≤(V+Nb) / (Fe+C+Co)≤0.21, 0.11≤(B+Si+Co) / (Ni+Cr)≤0.17.

[0024] Preferably, the alloy working layer comprises, by weight: 10-15 parts Fe, 8-15 parts Cr, 2.0-3.0 parts B, 2.0-3.0 parts Si, 2.0-3.0 parts C, 32-38 parts W, 1.0-2.0 parts Co, with the balance being Ni and trace impurities, 0.14≤(B+Si+Co) / (Ni+Cr)≤0.26, 0.64≤(Co+W) / (Ni+Cr+C)≤0.94.

[0025] The manufacturing process of straightening rollers involves the following steps:

[0026] Step 1, shot peening

[0027] The surface of the straightening roller is shot-peened, and the roughness after the treatment is Ra15~Ra35;

[0028] Step 2, roughening - initial spraying treatment

[0029] Powder 1 is prepared in proportion and then subjected to spiral roughening treatment on the surface of the straightening roller after spraying.

[0030] The forward-moving spiral coarsens to form a sinusoidal groove, and the reverse-moving spiral along the sinusoidal groove is processed by synchronously conveying powder and thermal spraying to obtain an alloy groove coating.

[0031] The straightening roller is deflected to a suitable angle, and the forward-moving spiral coarsens the second sinusoidal groove. The reverse-moving spiral, along the second sinusoidal groove, is simultaneously conveyed by powder and treated with thermal spraying to obtain the second alloy groove coating.

[0032] The components of powder one, by weight, include: 13-18 parts Fe, 15-18 parts Cr, 2.5-3.5 parts Co, 3.0-4.0 parts B, 3.0-4.0 parts Si, 0.4-0.8 parts C, 1.0-2.0 parts V, 1.0-2.0 parts Nb, with the balance being Ni and trace impurities. 0.11≤(V+Nb) / (Fe+C+Co)≤0.25, 0.09≤(B+Si+Co) / (Ni+Cr)≤0.19;

[0033] The depth of the first sinusoidal groove is at least 0.3 to 1 times the depth of the second sinusoidal groove;

[0034] Step 3, Final Spray Coating

[0035] Powder 2 is prepared in proportion, and the alloy working layer is obtained by thermal spraying on the surfaces of alloy groove coating 1, alloy groove coating 2 and the substrate after shot peening.

[0036] The components of powder 2, by weight, include: 10-13 parts Fe, 8-15 parts Cr, 3.0-4.0 parts B, 3.0-4.0 parts Si, 2.0-4.0 parts C, 32-36 parts W, 1.0-2.0 parts Co, with the balance being Ni and trace impurities. 0.13≤(B+Si+Co) / (Ni+Cr)≤0.28, 0.59≤(Co+W) / (Ni+Cr+C)≤0.96;

[0037] After spraying, the coating is remelted at a temperature of 1000~1200℃.

[0038] Immediately transfer to a fine furnace for annealing or isothermal tempering and recrystallization, with the temperature controlled between 600 and 650°C;

[0039] After annealing or tempering, the U-shaped roller is cooled to room temperature, and then subjected to precision machining and static and dynamic balancing to obtain the finished product.

[0040] After spiral roughening, the coating is sprayed into the roughened grooves. The resulting structural coatings are staggered and have different depths. The grooves sprayed first are deeper than those sprayed later, creating a staggered mesh structure. Both layers are coated with the same material. The interlayer bonding is optimized based on the specific ratio of each layer, ensuring effective connection. This also ensures the connection with the working layer. Remelting after spraying yields a semi-fused microalloy composite coating.

[0041] Preferably, the roughening-initial spraying treatment is completed using a straightening roller processing equipment. The straightening roller processing equipment includes a moving guide rail, on which two sets of traveling mechanisms and an integrated processing device fixed in the middle are arranged. A clamping mechanism is installed on the traveling mechanism, and the clamping mechanism is suitable for clamping and fixing the straightening roller.

[0042] The integrated processing device includes a frame, on which a reciprocating screw and a drive motor are mounted. The drive motor is mounted on the frame and is adapted to drive the reciprocating screw, which is rotatably mounted on the frame. A drive block is matched on the reciprocating screw and is adapted to reciprocate laterally relative to the frame. Multiple sliders are mounted on the frame, and driven rings with notches are mounted on the inner side of the multiple sliders. The driven rings and the drive blocks are engaged by teeth. A switching structure, a roughening structure, and a spraying structure are mounted on the driven rings. The switching structure is adapted to reciprocate to switch the roughening structure and the spraying structure to the working state.

[0043] Preferably, the switching structure includes a switching frame, which is rotatably mounted on the driven ring via a hinge seat. An angle limiting part is installed between the switching frame and the hinge seat. The switching frame completes the reciprocating angle switching between the angle limiting part and the hinge seat. A blocking structure is clamped on the roller body. The blocking structure is adapted to unidirectionally prevent the switching frame from moving in the opposite direction and to complete the angle switching via the angle limiting part.

[0044] Preferably, the spraying structure includes an adjustment frame and a flame sprayer or plasma sprayer, the adjustment frame being selectively adjustable relative to the switching frame, and the flame sprayer or plasma sprayer being mounted on the adjustment frame.

[0045] Preferably, the roughening structure includes a driver and a tool holder mounted on a switching frame, wherein the output end of the driver is connected to the tool holder via a worm gear, and the tool holder is rotatably mounted on the switching frame.

[0046] Preferably, the specific steps of the roughening-initial spraying treatment are as follows:

[0047] The straightening roller is hoisted and fixed by a clamping mechanism, which is equipped with a rotary spindle that can drive the clamping mechanism and the straightening roller to rotate.

[0048] The traveling mechanism moves the straightening roller, which is fixed by the clamping mechanism, into the integrated processing device. The integrated processing device is equipped with a separate enclosed shot peening chamber and a clean room. The roller surface shot peening and cleaning treatment are completed in sequence by relying on the traveling mechanism.

[0049] The traveling mechanism moves the straightening roller to the frame, and the drive motor drives the reciprocating screw to rotate, which in turn drives the slider on it to reciprocate, thereby driving the driven coil to reciprocate. The driver on the roughening structure drives the tool holder to deflect in time, and finally the first sinusoidal groove is obtained on the roller surface. When the switching frame passes through the blocking structure, the traveling mechanism moves in the opposite direction. The switching frame completes the angle switching under the action of the blocking structure, and is restricted by the angle limiting part, and then the first powder is sprayed to obtain the first alloy groove coating.

[0050] After the switching frame passes the blocking structure at the other end, the clamping mechanism drives the straightening roller to rotate at a reasonable angle, and then the traveling mechanism moves forward again. The switching frame completes the angle switching under the action of the blocking structure and is restricted by the angle limiting part. The roughening structure is in working state. The driver on the roughening structure drives the tool holder to deflect in time, and finally the second sinusoidal groove is obtained on the roller surface. After the switching frame passes the blocking structure, the traveling mechanism moves in the opposite direction. The switching frame completes the angle switching under the action of the blocking structure and is restricted by the angle limiting part. The first powder is sprayed to obtain the second alloy groove coating.

[0051] Compared with the prior art, the present invention has the following beneficial effects:

[0052] 1) By optimizing the ratio to 0.09≤(B+Si+Co) / (Ni+Cr), the coating achieves high hardness, wear resistance, and heat corrosion resistance. Specifically, Si melts into the alloy matrix, providing solid solution strengthening; Co possesses excellent corrosion resistance, heat resistance, and oxidation resistance; B and Co combine with Ni and / or Cr in the matrix to form hard metal compounds, resulting in dispersed distribution and dispersion strengthening within the alloy. Ensuring precise Co content also promotes the precipitation of dispersed chromium-carbon and boron-chromium hard phases, and facilitates carbide formation at high temperatures. This comprehensive combination enhances the hardness and wear resistance of the cemented carbide, maintaining high hardness, oxidation resistance, impact resistance, thermal shock resistance, and corrosion resistance even at high temperatures. It also improves the coating's spraying process performance and increases the deposition rate.

[0053] 2) Based on the above-mentioned proportions, the proportions were optimized to meet the condition 0.11 ≤ (V+Nb) / (Fe+C+Co) ≤ 0.25. V and Nb were introduced into the original proportions and precisely adjusted to fit within the above range, resulting in the formation of a nanoscale carbide second phase within the coating. This significantly reduced the coating's overheat sensitivity, refined the grains, and resulted in a fine microstructure and high strength and toughness after quenching. However, the precise formulation of Co content slightly affected the grain refinement effect, as the introduction of V and Nb resulted in the formation of multiple metals within the coating. Compound phases, such as VCo5, ​​VCo3, NbCo2, NbCo5, VNb2, and VNb5, can act as nucleation sites for heterogeneous grains during alloy solidification, promoting grain nucleation and growth, resulting in finer grains. These compound phases can further refine grains by hindering grain growth and suppressing grain boundary movement, altering grain boundary structure, reducing impurity element segregation at grain boundaries, suppressing second temper embrittlement, and improving red hardness. The resulting coating exhibits high strength, high hardness, good corrosion resistance, and high-temperature stability. This overcomes the traditional bias of adding rare earth elements to alloy components to refine grains, alter grain boundary structure, and suppress temper embrittlement.

[0054] 3) The principle of optimizing the proportions to meet the condition 0.13≤(B+Si+Co) / (Ni+Cr)≤0.28 is the same as above. Sufficient W is added to the working layer raw material while increasing the C content, relatively reducing the content of B, Si, Co, and Cr, and meeting the condition 0.59≤(Co+W) / (Ni+Cr+C)≤0.96. This results in the formation of a tungsten-cobalt-carbon compound phase within the coating. This phase, along with B and Co, combines with Ni and / or Cr in the matrix to form hard metal compounds, resulting in a dispersed distribution within the alloy and providing dispersion strengthening. By combining B to promote the precipitation of dispersed chromium-carbon and boron-chromium hard phases and to promote the formation of carbides at high temperatures, the overall formulation can improve the hardness and wear resistance of cemented carbide. This results in high hardness at high temperatures, as well as good oxidation resistance, impact resistance, thermal shock resistance, and corrosion resistance. It also improves the coating process performance of the alloy and increases the deposition rate, resulting in better toughness and ductility, oxidation and acid corrosion resistance, crack resistance, and thermal shock resistance. Furthermore, it achieves high wear resistance, high-temperature hardness, strength, and other properties, and is resistant to intergranular corrosion and thermal shock.

[0055] 4) A roughening initial stage spraying is implemented in an alternating manner to obtain an interlaced skeleton network on the roller surface. The depth difference between the two sinusoidal grooves in the skeleton network can be used to achieve effective bonding at the intersection point, ensuring a relatively consistent bonding surface. In conjunction with the shot peening area, a working layer is sprayed on the surface. This working layer can absorb the structural stress during operation by the embedded skeleton network, and at the same time improve the bonding strength between the roller surface and the coating. With the enhanced bonding ability, combined with the matrix material, it has excellent spraying process performance and improved deposition efficiency.

[0056] 5) After the switching frame touches the blocking structure, the angle is switched through the angle limiting part. After the angle is switched, the angle is fixed through the angle limiting part, thereby realizing the exchange of the roughening structure and the spraying structure. This allows the roughening and preliminary spraying to be carried out alternately. The roughening and preliminary spraying treatment on the roller surface are carried out circumferentially. After the network skeleton is obtained on the roller surface, the working layer is obtained by circumferential spraying along the axis. The tungsten carbide in the working layer achieves the properties of oxidation resistance, impact resistance, and high temperature corrosion resistance.

[0057] 6) The present invention employs two sets of walking mechanisms. One set completes the clamping and roughening-initial spraying treatment by the integrated processing device, while the other set performs the final spraying treatment. This allows the entire process of shot peening, roughening, and spraying to be completed in a single clamping, eliminating the need for multiple clamping operations. In particular, the performance of the straightening rollers is superior during the roughening and initial spraying stages. Attached Figure Description

[0058] Figure 1 This is a schematic diagram of the structure of the outer alloy working layer of the straightening roller of the present invention after peeling off the thickness.

[0059] Figure 2 This is a schematic diagram of the overall structure of the integrated device of the present invention.

[0060] Figure 3 This is a front view of the overall structure of the walking mechanism and clamping mechanism on one side of the present invention.

[0061] Figure 4 This is a side view of the walking mechanism in this invention.

[0062] Figure 5 This is a schematic diagram of the internal structure of the integrated processing device in this invention.

[0063] Figure 6 for Figure 5 A schematic diagram of the switching frame, roughening structure, and spraying structure.

[0064] Figure 7 for Figure 6 A schematic diagram of the angle limiting section at the joint of the hinged seat and the switching frame.

[0065] Figure 8 for Figure 5 A side cross-sectional view of the frame.

[0066] Figure 9 for Figure 5 A partial structural diagram of the central blocking structure. Detailed Implementation

[0067] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0068] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0069] Example 1, such as Figure 1 As shown, the impact-resistant and wear-resistant superhard metal matrix composite layer includes alloy groove coating 1 30, alloy groove coating 2 40 and alloy working layer 20.

[0070] Both alloy trench cladding layer 1 30 and alloy trench cladding layer 2 40 have sinusoidal structures, are staggered, and have at least one set of intersection nodes between them. They are located inside the alloy working layer 20.

[0071] The components of Alloy Trench Coating 1 30 and Alloy Trench Coating 2 40, by weight, include: 13 parts Fe, 15 parts Cr, 2.5 parts Co, 3.0 parts B, 3.0 parts Si, 0.6 parts C, 1.0 part V, 1.0 part Nb, with the balance being Ni and trace impurities, 0.12≤(V+Nb) / (Fe+C+Co)≤0.21, 0.11≤(B+Si+Co) / (Ni+Cr)≤0.17.

[0072] The alloy working layer 20 comprises, by weight: 15 parts Fe, 13 parts Cr, 2.0 parts B, 2.0 parts Si, 3.0 parts C, 38 parts W, 1.0 part Co, with the balance being Ni and trace impurities, 0.11≤(B+Si+Co) / (Ni+Cr)≤0.21, 0.64≤(Co+W) / (Ni+Cr+C)≤0.94.

[0073] Example 2 differs from Example 1 in that:

[0074] The components of Alloy Trench Coating 1 30 and Alloy Trench Coating 2 40, by weight, include: 14 parts Fe, 18 parts Cr, 3.0 parts Co, 3.5 parts B, 3.5 parts Si, 0.6 parts C, 1.5 parts V, 1.5 parts Nb, with the balance being Ni and trace impurities, 0.12≤(V+Nb) / (Fe+C+Co)≤0.21, 0.11≤(B+Si+Co) / (Ni+Cr)≤0.17.

[0075] The alloy working layer 20 comprises, by weight: 12 parts Fe, 10 parts Cr, 2.5 parts B, 2.5 parts Si, 2.5 parts C, 35 parts W, 2.0 parts Co, with the balance being Ni and trace impurities, 0.11≤(B+Si+Co) / (Ni+Cr)≤0.21, 0.64≤(Co+W) / (Ni+Cr+C)≤0.94.

[0076] Example 3 differs from Example 1 in that:

[0077] The components of Alloy Trench Coating 1 30 and Alloy Trench Coating 2 40, by weight, include: 14 parts Fe, 16 parts Cr, 2.8 parts Co, 3.0 parts B, 3.0 parts Si, 0.6 parts C, 1.8 parts V, 1.8 parts Nb, with the balance being Ni and trace impurities, 0.12≤(V+Nb) / (Fe+C+Co)≤0.21, 0.11≤(B+Si+Co) / (Ni+Cr)≤0.17.

[0078] The alloy working layer 20 comprises, by weight: 10 parts Fe, 10 parts Cr, 2.5 parts B, 2.5 parts Si, 2.5 parts C, 34 parts W, 1.5 parts Co, with the balance being Ni and trace impurities, 0.11≤(B+Si+Co) / (Ni+Cr)≤0.21, 0.64≤(Co+W) / (Ni+Cr+C)≤0.94.

[0079] After being put into use in steel mills, with a steel throughput of around 850,000 tons, its service life has been increased by about 6 times. Compared with other grades of nickel-based alloy coated straightening rolls, its service life has been increased by about 30-50%, and it has properties such as heat resistance, corrosion resistance, oxidation resistance, wear resistance, high temperature erosion resistance, high temperature hardness, and strength. It can also resist intergranular corrosion, thermal shock, and other properties, making it particularly suitable for fully covering steel rolling conveying areas.

[0080] Example 4, manufacturing process of straightening roller, the manufacturing steps are as follows:

[0081] Step 1, shot peening

[0082] The surface of the straightening roller is shot-peened, and the roughness after the treatment is Ra15~Ra35;

[0083] Step 2, roughening - initial spraying treatment

[0084] Powder 1 is prepared in proportion and then subjected to spiral roughening treatment on the surface of the straightening roller after spraying.

[0085] The forward motion spiral coarsens the first sinusoidal groove, and the reverse motion along the first sinusoidal groove is processed by synchronously conveying powder and thermal spraying to obtain the alloy groove coating 30.

[0086] The straightening roller is deflected to a suitable angle, and the forward-moving spiral coarsens the second sinusoidal groove. The reverse-moving spiral, along the second sinusoidal groove, is simultaneously conveyed by powder and treated with thermal spraying to obtain the second alloy groove coating 40.

[0087] The composition of powder one is the same as that of alloy groove coating one 30 and alloy groove coating two 40 in the above embodiments.

[0088] The depth of the first sinusoidal groove is at least 0.3 to 1 times the depth of the second sinusoidal groove;

[0089] Step 3, Final Spray Coating

[0090] Powder 2 is prepared in proportion and then thermally sprayed onto alloy groove coating 30, alloy groove coating 40 and the surface of the substrate after shot peening to obtain alloy working layer 20.

[0091] The composition of powder two is the same as that of alloy working layer 20 in the above embodiment;

[0092] After spraying, a semi-fused microalloy composite coating is obtained by remelting at a temperature of 1000~1200℃.

[0093] Immediately transfer to a fine furnace for annealing or isothermal tempering and recrystallization, with the temperature controlled between 600 and 650°C;

[0094] After annealing or tempering, the straightening rollers are cooled to room temperature, and then subjected to precision machining and static and dynamic balancing to obtain the finished product.

[0095] Example 5, as Figures 2 to 9 As shown, the roughening-initial spraying treatment is completed using a straightening roller processing equipment. The straightening roller processing equipment includes a moving guide rail 10, on which two sets of traveling mechanisms 11 and an integrated processing device fixed in the middle are provided. A clamping mechanism 12 is installed on the traveling mechanism 11, and the clamping mechanism 12 is suitable for clamping and fixing the straightening roller.

[0096] The integrated processing device includes a frame 13, on which a reciprocating screw 15 and a drive motor 14 are mounted. The drive motor 14 is mounted on the frame 13 and is adapted to drive the reciprocating screw 15, which is rotatably mounted on the frame 13. A drive block 16 is matched on the reciprocating screw 15. The drive block 16 is adapted to reciprocate laterally relative to the frame 13. Multiple sliders 18 are mounted on the frame 13. A driven ring 17 with a notch is mounted on the inner side of the multiple sliders 18. The notch allows the clamping mechanism 12 to pass freely. The driven ring 17 and the drive block 16 are engaged by teeth. A switching structure, a roughening structure and a spraying structure are mounted on the driven ring 17. The switching structure is adapted to reciprocate to switch the roughening structure and the spraying structure to the working state.

[0097] The switching structure includes a switching frame 19, which is an electrically or pneumatically telescopic structure, such as an electric push rod or a cylinder. The switching frame 19 is in a retracted state during shot peening and cleaning, and in an extended state during roughening-initial spraying treatment, so as to ensure that the roughening structure can perform spiral roughening treatment on the roller surface and the spraying part can perform groove spraying treatment. The switching frame 19 is rotatably mounted on the driven ring 17 via the hinge seat 111. An angle limiting part 110 is installed between the switching frame 19 and the hinge seat 111. The switching frame 19 completes the angle reciprocating switching between the angle limiting part 110 and the hinge seat 111. A blocking structure 112 is clamped on the roller body. The blocking structure 112 includes multiple individual parts that are clamped and installed on the stepped shaft of the roller body by steel strips. The blocking structure 112 is adapted to unidirectionally prevent the switching frame 19 from moving in the opposite direction and complete the angle switching via the angle limiting part 110. The blocking structure 112 is a single-unit rotating structure, consisting of a main body 1121 and a blocking body 1122 rotatably mounted on the top of the main body. A torsion spring (not shown in the figure) is installed at the rotation node of the two. A limiting plate 1123 is installed on the top of the main body 1121 to limit the angle of the blocking body 1122 after it has deflected and reset in the opposite direction, that is, the blocking body 1122 remains vertical after reset. The angle limiting part 110 includes a guide groove 1101 provided on the hinge seat 111 and positioning grooves 1102 located at both ends of the guide groove 1101, as well as an elastic positioning pin installed on the switching frame 19. The elastic positioning pin is adapted to rotate along the guide groove 1101 and is fitted and fixed in the positioning groove 1102. When the blocking structure 112 obstructs the switching frame 19, it can release the positioning groove 1102 and the elastic positioning pin, allowing it to rotate to another positioning groove 1102 to complete the angle limiting.

[0098] The spraying structure includes an adjusting frame 113 and a flame sprayer or plasma sprayer. The adjusting frame 113 is selectively adjustable in position relative to the switching frame 19. The flame sprayer or plasma sprayer is mounted on the adjusting frame 113. The adjusting frame 113 is linearly adjustable relative to the switching frame 19, and the switching frame 19 is equipped with a pusher, which can be a cylinder, to selectively adjust the position of the adjusting frame 113. The sprayer is equipped with two powder tubes and a heat source nozzle. The angle of the two powder tubes relative to the heat source nozzle is adjustable. The adjustable angle structure is consistent with the powder tube angle structure of conventional sprayers and is not shown in the figure. The two powder tubes are respectively suitable for powder feeding of powder one and powder two.

[0099] The roughening structure includes a driver 115 and a tool holder 114 mounted on a switching frame 19. The output end of the driver 115 is connected to the tool holder 114 via a worm gear. The tool holder 114 is rotatably mounted on the switching frame 19. The driver 115 uses a servo motor, which can adjust the travel angle of the tool holder 114 in real time. A cutting tool is mounted on the tool holder 114 to be suitable for helical roughening of the roller surface.

[0100] The clamping mechanism 12 is equipped with a rotary spindle, which can drive the clamping mechanism 12 and the straightening roller to rotate.

[0101] The integrated processing device is also equipped with a separate enclosed shot blasting chamber 116 and a clean room 117. Both the shot blasting chamber 116 and the clean room 117 are equipped with automatic closing doors on the sides facing the traveling mechanism 11. The roller shot blasting and cleaning treatment are completed sequentially by relying on the traveling mechanism 11.

[0102] Example 6, as Figures 2 to 9 As shown, the roughening-initial spraying treatment steps are as follows:

[0103] The straightening roller is hoisted and fixed by the clamping mechanism 12, which is equipped with a rotary spindle that can drive the clamping mechanism 12 and the straightening roller to rotate.

[0104] The traveling mechanism 11 moves the straightening roller fixed by the clamping mechanism 12 into the integrated processing device. The integrated processing device is equipped with a separate enclosed shot blasting chamber 116 and a clean room 117. The roller surface shot blasting and cleaning are completed in sequence by relying on the traveling mechanism 11. During this process, the switching frame 19 is in a retracted state.

[0105] The traveling mechanism 11 moves the straightening roller to the frame 13 and locks it in place. The switching frame 19 changes from the retracted state to the extended state. The roughening structure is in working state. The drive motor 14 drives the reciprocating screw 15 to rotate, which drives the slider 18 on it to move back and forth. This drives the driven coil 17 to deflect back and forth. The driver 115 on the roughening structure drives the tool holder 114 to deflect in time. Finally, a sinusoidal groove is obtained on the roller surface. When the switching frame 19 passes the blocking structure 112, the traveling mechanism 11 moves in the opposite direction. The switching frame 19 completes the angle switching under the action of the blocking structure 112 and is restricted by the angle limiting part 110. Powder is sprayed to obtain alloy groove coating 30.

[0106] After the switching frame 19 passes the blocking structure 112 at the other end, the clamping mechanism 12 drives the straightening roller to rotate at a reasonable angle, and the traveling mechanism 11 moves forward again. The switching frame 19 completes the angle switching under the action of the blocking structure 112 and is restricted by the angle limiting part 110. The roughening structure is in working state. The driver 115 on the roughening structure drives the tool holder 114 to deflect in time. Finally, the second sinusoidal groove is obtained on the roller surface. After the switching frame 19 passes the blocking structure 112, the traveling mechanism 11 moves in the opposite direction. The switching frame 19 completes the angle switching under the action of the blocking structure 112 and is restricted by the angle limiting part 110. The first powder is sprayed to obtain the second alloy groove coating 40.

[0107] Remove the blocking structure 112, start the rotating spindle of the clamping mechanism 12, close the powder pipe for conveying the bottom layer, open the powder pipe for conveying the working layer, and carry out the spraying operation of the working layer by adjusting the position of the adjusting frame 113 and the powder feeding direction and position of the working layer powder until completion. Release the position lock of the traveling mechanism 11, move out of the working position and remove the straightening roller.

[0108] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. The substitutions may be replacements of some structures, devices, or method steps, or they may be complete technical solutions. Equivalent substitutions or modifications made to the technical solutions and inventive concepts of the present invention should all be covered within the scope of protection of the present invention.

Claims

1. A manufacturing process for straightening rollers, characterized in that, The production steps are as follows: Step 1, shot peening The surface of the straightening roller is shot-peened, and the roughness after the treatment is Ra15~Ra35; Step 2, roughening - initial spraying treatment Powder 1 is prepared in proportion and then subjected to spiral roughening treatment on the surface of the straightening roller after spraying. The forward-moving spiral coarsens to form a sinusoidal groove, and the reverse-moving spiral along the sinusoidal groove is processed by synchronously conveying powder and thermal spraying to obtain an alloy groove coating. The straightening roller is deflected to a suitable angle, and the forward-moving spiral coarsens the second sinusoidal groove. The reverse-moving spiral, along the second sinusoidal groove, is simultaneously conveyed by powder and treated with thermal spraying to obtain the second alloy groove coating. The components of powder one, by weight, include: 13-18 parts Fe, 15-18 parts Cr, 2.5-3.5 parts Co, 3.0-4.0 parts B, 3.0-4.0 parts Si, 0.4-0.8 parts C, 1.0-2.0 parts V, 1.0-2.0 parts Nb, with the balance being Ni and trace impurities. 0.11≤(V+Nb) / (Fe+C+Co)≤0.25, 0.09≤(B+Si+Co) / (Ni+Cr)≤0.19; The depth of the first sinusoidal groove is at least 0.3 to 1 times the depth of the second sinusoidal groove; Step 3, Final Spray Coating Powder 2 is prepared in proportion, and the alloy working layer is obtained by thermal spraying on the surfaces of alloy groove coating 1, alloy groove coating 2 and the substrate after shot peening. The components of powder 2, by weight, include: 10-13 parts Fe, 8-15 parts Cr, 2.0-3.0 parts B, 2.0-3.0 parts Si, 2.0-4.0 parts C, 32-36 parts W, 1.0-2.0 parts Co, with the balance being Ni and trace impurities. 0.13≤(B+Si+Co) / (Ni+Cr)≤0.28, 0.59≤(Co+W) / (Ni+Cr+C)≤0.96; After spraying, the coating is remelted at a temperature of 1000~1200℃. Immediately transfer to a fine furnace for annealing or isothermal tempering and recrystallization, with the temperature controlled between 600 and 650°C; After annealing or tempering, the straightening rollers are cooled to room temperature, and then subjected to precision machining and static and dynamic balancing to obtain the finished product.

2. The straightening roller manufacturing process according to claim 1, characterized in that, The components of the powder, by weight, include: 13-18 parts Fe, 15-18 parts Cr, 2.5-3.5 parts Co, 3.0-4.0 parts B, 3.0-4.0 parts Si, 0.4-0.8 parts C, 1.0-2.0 parts V, 1.0-2.0 parts Nb, with the balance being Ni and trace impurities, 0.12≤(V+Nb) / (Fe+C+Co)≤0.21, 0.11≤(B+Si+Co) / (Ni+Cr)≤0.

17.

3. The straightening roller manufacturing process according to claim 2, characterized in that, The roughening-initial spraying treatment is completed using a straightening roller processing equipment. The straightening roller processing equipment includes a moving guide rail, on which two sets of traveling mechanisms and an integrated processing device fixed in the middle are arranged. A clamping mechanism is installed on the traveling mechanism, which is suitable for clamping and fixing the straightening roller. The integrated processing device includes a frame, on which a reciprocating screw and a drive motor are mounted. The drive motor is mounted on the frame and is adapted to drive the reciprocating screw, which is rotatably mounted on the frame. A drive block is matched on the reciprocating screw and is adapted to reciprocate laterally relative to the frame. Multiple sliders are mounted on the frame, and driven rings with notches are mounted on the inner side of the multiple sliders. The driven rings and the drive blocks are engaged by teeth. A switching structure, a roughening structure, and a spraying structure are mounted on the driven rings. The switching structure is adapted to reciprocate to switch the roughening structure and the spraying structure to the working state.

4. The manufacturing process of the straightening roller according to claim 3, characterized in that, The switching structure includes a switching frame, which is rotatably mounted on the driven ring via a hinge seat. An angle limiting part is installed between the switching frame and the hinge seat. The switching frame completes the reciprocating angle switching between the angle limiting part and the hinge seat. A blocking structure is clamped on the roller body. The blocking structure is suitable for unidirectionally hindering the switching frame from moving in the opposite direction and completing the angle switching via the angle limiting part.

5. The manufacturing process of the straightening roller according to claim 4, characterized in that, The spraying structure includes an adjustment frame and a flame sprayer or plasma sprayer. The adjustment frame is adapted to be selectively adjustable relative to the switching frame, and the flame sprayer or plasma sprayer is mounted on the adjustment frame.

6. The manufacturing process of the straightening roller according to claim 5, characterized in that, The roughening structure includes a driver and a tool holder mounted on a switching frame. The output end of the driver is connected to the tool holder via a worm gear, and the tool holder is rotatably mounted on the switching frame.

7. The straightening roller manufacturing process according to claim 6, characterized in that, The clamping mechanism is equipped with a rotary spindle, which can drive the clamping mechanism and the straightening roller to rotate. The integrated processing unit is also equipped with a separate enclosed shot blasting chamber and a clean room. Both the shot blasting chamber and the clean room are equipped with automatic closing doors on the sides facing the traveling mechanism. The roller shot blasting and cleaning treatment are completed sequentially by relying on the traveling mechanism.

8. The straightening roller manufacturing process according to claim 7, characterized in that, The specific steps of the roughening-initial spraying treatment are as follows: The straightening roller is hoisted and fixed by a clamping mechanism, which is equipped with a rotary spindle that can drive the clamping mechanism and the straightening roller to rotate. The traveling mechanism moves the straightening roller, which is fixed by the clamping mechanism, into the integrated processing device. The integrated processing device is equipped with a separate enclosed shot peening chamber and a clean room. The roller surface shot peening and cleaning treatment are completed in sequence by relying on the traveling mechanism. The traveling mechanism moves the straightening roller to the frame, and the drive motor drives the reciprocating screw to rotate, which in turn drives the slider on it to reciprocate, thereby driving the driven coil to reciprocate. The driver on the roughening structure drives the tool holder to deflect in time, and finally the first sinusoidal groove is obtained on the roller surface. When the switching frame passes through the blocking structure, the traveling mechanism moves in the opposite direction. The switching frame completes the angle switching under the action of the blocking structure, and is restricted by the angle limiting part, and then the first powder is sprayed to obtain the first alloy groove coating. After the switching frame passes the blocking structure at the other end, the clamping mechanism drives the straightening roller to rotate at a reasonable angle, and then the traveling mechanism moves forward again. The switching frame completes the angle switching under the action of the blocking structure and is restricted by the angle limiting part. The roughening structure is in working state. The driver on the roughening structure drives the tool holder to deflect in time, and finally the second sinusoidal groove is obtained on the roller surface. After the switching frame passes the blocking structure, the traveling mechanism moves in the opposite direction. The switching frame completes the angle switching under the action of the blocking structure and is restricted by the angle limiting part. The first powder is sprayed to obtain the second alloy groove coating.

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