Method for manufacturing or repairing, work roll, rolling stand, metal strip and application device for applying particles

Abstract

The invention relates to a method for manufacturing or repairing a work roll (100) comprising a substrate (102) and a wear protection layer (104), wherein particles (112) are thermally applied to the work roll (100), wherein the method is characterized in that during the thermal application of the particles 50% or more of the particles remain adhered to the substrate and / or to the already applied wear protection layer and stay on the substrate and / or on the wear protection layer, preferably 60% or more, or 75% or more, particularly preferably 80% or more.

Description

[0001] The present invention relates to a method for manufacturing or repairing work rolls, comprising a substrate and an abrasion-resistant protective layer, wherein a coating material containing particles is thermally applied to the substrate.

[0002] The present invention also relates to a work roll for rolling metal products, having a base and a wear-resistant protective layer.

[0003] The present invention also relates to a rolling mill stand for processing metal products such as metal strips.

[0004] The present invention also relates to a metal strip.

[0005] The present invention also relates to an application device for applying particles onto a substrate of a work roll, comprising a burner device and a control and / or adjustment device for controlling and / or adjusting the application device.

[0006] Common methods for manufacturing or repairing work rolls are known from the prior art.

[0007] The purpose of this invention is to propose an improvement or alternative to the existing technology.

[0008] According to a first aspect, the object of the invention is achieved by a method for manufacturing or repairing a work roll, comprising a substrate and an abrasion-resistant protective layer, wherein a coating material containing particles is thermally applied to the work roll, wherein the method is characterized in that, during the thermal application of the particles, 50% or more of the particles remain adhered to the substrate and / or the applied abrasion-resistant protective layer and remain on the substrate and / or the abrasion-resistant protective layer, preferably 60% or more, or 75% or more, particularly preferably 80% or more.

[0009] Because this method successfully adheres at least about 50% of the particles to the substrate or its wear-resistant protective layer without loss, it can be used particularly efficiently for manufacturing or repairing work rolls or wear-resistant protective layers, especially in a particularly resource-efficient manner.

[0010] Existing manufacturing methods for this type of general-purpose work roll operate with a huge loss of approximately 50% or more of particles because the relevant particles are often only insufficiently adhered when impacting the surface of the work roll, and are therefore lost and / or do not reach the surface of the work roll during the coating process, but instead miss the component, particularly interacting with the airflow around the surface of the work roll, and especially with the local turbulence on the path of the particles from the outlet nozzle of the burner equipment toward the surface of the work roll.

[0011] Due to their complex structure, non-adhesive particulate mixtures are almost impossible to reuse, especially when combined with processing by heat application methods, because reuse would require separating the particulate mixture into pure substances again and / or the pure substances would have to be regranulated.

[0012] By utilizing this invention, the existing drawbacks of the prior art can be significantly reduced or even completely avoided.

[0013] In particular, the application efficiency can also be determined by selecting the application device or its process burner.

[0014] This manufacturing and / or repair method is a heat application method, more precisely a thermal spraying method, for applying particles thermally onto a substrate and / or an existing wear-resistant protective layer on a work roll used for rolling metal products such as metal strips.

[0015] First, it should be noted that in the context of this patent application, indefinite articles and indefinite numbers, such as “one…”, “two…”, etc., should generally be understood as minimum values, i.e., “at least one…”, “at least two…”, etc., unless it can be clearly seen from the context or the specific text of a particular paragraph, for example, only “exactly one…”, “exactly two…”, etc.

[0016] In this regard, it should also be mentioned that, in the context of this patent application, the expression “in particular” is always understood to mean that the expression introduces optional, preferred features. The expression should not be construed as “exactly” or “that is”.

[0017] In the context of this invention, the particles can have different designs, but are preferably ceramic particles and / or metal particles. Other particles may also be provided as functional materials, additives, or fillers, if desired.

[0018] In this case, particles or mixtures of particles can be provided in powder form as starting materials for generating a wear-resistant protective layer.

[0019] In this respect, granules or granule mixtures can be processed into powder and accordingly provided or processed in powder form on an application device.

[0020] According to the first variant of the particles provided in powder form, the particles can also be provided in a suspension as a starting material for generating a wear-resistant protective layer.

[0021] The suspension comprises particles dispersed in a liquid phase. The liquid phase may contain water and / or ethanol and / or isopropanol and / or the like. In particular, a liquid phase with a low enthalpy of vaporization may be used, especially one with an enthalpy of vaporization of less than or equal to 2.5 kJ / g.

[0022] In addition, the suspension may contain dispersants, especially citric acid, HNO3, diammonium citrate, C5H8O2, etc.

[0023] The suspension partially evaporates under the thermal energy of the hot gas flow generated by the burner equipment. This partial evaporation typically occurs before the suspension comes into contact with the matrix and / or the wear-resistant protective layer, particularly before the heat is applied to the particles obtained in this manner. In this respect, the particles do not evaporate, but the liquid phase and / or dispersant evaporate. In this respect, particles or a mixture of particles may also be provided as a suspension on the burner equipment in the context of this specification.

[0024] It has been found that using suspensions can produce wear-resistant protective layers with low roughness values ​​and / or low porosity and / or particularly high hardness.

[0025] According to a second variation of the granules provided in powder form, the granules can also be provided in wire and / or rod form as a starting material for producing a wear-resistant protective layer. The corresponding wire (filler wire) or rod (filler rod) used to provide the granules can have a sheath and granules surrounded by the sheath.

[0026] When using wires or bars as starting materials for thermally applying a wear-resistant protective layer, the starting material can be melted by a hot gas flow provided by the burner equipment and / or by plasma generated between the anode and cathode. This typically occurs before the particles obtained in this way come into contact with the matrix and / or the wear-resistant protective layer, i.e., particularly before thermal application to the particles obtained in this way. In this respect, particles or particle mixtures may also be provided as wires and / or bars on the burner equipment in the context of this specification.

[0027] Suitable particles can be formed as hard phase or hard phase particles and / or matrix or matrix particles.

[0028] In the context of this invention, the term "hard phase" describes harder particles embedded in a wear-resistant protective layer within a softer matrix, wherein the softer matrix is ​​formed using matrix particles during a thermal spraying process.

[0029] In this case, the hard phase suitable for the wear-resistant protective layer can be, in particular, an oxide, carbide, or boride hard phase, which advantageously has high hardness. For example, a compound of silicon and carbon that forms silicon carbide (SiC) can be used.

[0030] Therefore, the term "matrix" describes the structure on which the hard phase is carried on the wear-resistant protective layer. Thus, the hard phase is embedded in the matrix.

[0031] Both the hard phase and the matrix can be provided by the corresponding particles in the powdered starting material.

[0032] The hard phase particles are particularly preferred to have a proportion of tungsten carbide (WC) greater than or equal to 50% by weight, preferably greater than or equal to 60% by weight, and particularly preferably greater than or equal to 70% by weight.

[0033] In the context of this application, tungsten carbide (WC) is explicitly understood to be tungsten carbide monocarbide (WC).

[0034] The hardness of the wear-resistant protective layer can be advantageously increased by the weight proportion of tungsten carbide in the wear-resistant protective layer, especially as a component of the hard phase of the wear-resistant protective layer. In particular, the increase in the proportion of monotungsten carbide (WC) in the wear-resistant protective layer allows for a further increase in the hardness of the wear-resistant protective layer.

[0035] The wear-resistant protective layer can advantageously have a tungsten carbide (WC) content of 2% or more by weight, preferably 20% or more by weight, particularly preferably 25% or more by weight or 30% or more by weight. Furthermore, the wear-resistant protective layer can advantageously have a tungsten carbide (WC) content of 40% or more by weight, preferably 45% or more by weight, particularly preferably 65% ​​or more by weight or 70% or more by weight. Particularly advantageously, the wear-resistant protective layer can have a tungsten carbide (WC) content of 75% or more by weight, preferably 80% or more by weight, particularly preferably 85% or more by weight or 87% or more by weight.

[0036] Preferably, the wear-resistant protective layer comprises tungsten carbide (WC), alumina (Al2O3), zirconium oxide (ZrO2), chromium carbide (Cr3C2, Cr7C3 and / or Cr... 23 At least one, two, three, four, five, six, seven or more elements selected from C6), vanadium carbide (VC), silicon carbide (SiC), tungsten boride (WB), chromium oxide (CrO, Cr2O3, CrO2 and / or CrO3), titanium carbide (TiC), titanium oxide (TiO, Ti2O3 and / or TiO2) or molybdenum carbide (Mo2C and / or MoC), particularly tungsten carbide (WC), aluminum oxide (Al2O3), zirconium oxide (ZrO2), chromium carbide (Cr3C2, Cr7C3 and / or Cr2O3), vanadium carbide (VC), silicon carbide (SiC), tungsten boride (WB), chromium oxide (CrO, Cr2O3, CrO2 and / or Cr2O3), titanium carbide (TiC), titanium oxide (TiO, Ti2O3 and / or TiO2), or molybdenum carbide (Mo2C and / or MoC). 23 One, two, three, four or more elements selected from C6 and / or vanadium carbide (VC).

[0037] The matrix particles contain iron and / or nickel and / or cobalt and / or molybdenum and / or boron and / or tungsten, wherein the composition of the matrix particles also substantially corresponds to the composition of the matrix of the wear-resistant protective layer made from the matrix particles.

[0038] By using iron as a component of the matrix in the wear-resistant protective layer made from matrix particles, a relatively inexpensive matrix for the wear-resistant protective layer can be advantageously obtained. This can be particularly advantageous, especially when the wear-resistant protective layer of the work roll wears out faster than it corrodes.

[0039] Nickel, as a component of the matrix particles, is also a component of the matrix of the wear-resistant protective layer, which can improve the chemical resistance of the matrix. Depending on the alloy of the wear-resistant protective layer, using a nickel-containing matrix can achieve overall chemical resistance, especially corrosion resistance, of the wear-resistant protective layer.

[0040] Cobalt, as a component of the matrix particles, also serves as a component of the wear-resistant protective layer's matrix, leading to increased temperature resistance. Cobalt can also advantageously increase the hardness of the matrix, thereby increasing the overall hardness of the wear-resistant protective layer.

[0041] Molybdenum, as a component of the matrix particles, and thus also as a component of the matrix of the wear-resistant protective layer, can improve the wear-resistant protective layer, especially the chemical resistance and / or temperature resistance of the matrix.

[0042] If the matrix contains tungsten, it is beneficial to the temperature resistance of the matrix and therefore to the entire wear-resistant protective layer, making it advantageous for tungsten to be a component of the matrix particles.

[0043] It has been found that the adhesive properties of the matrix, and therefore the adhesive properties of the wear-resistant protective layer itself, can be improved by boron as a matrix component, thus boron is advantageous as a component of matrix particles.

[0044] In addition, the matrix particles and thus the matrix of the wear-resistant protective layer may also contain manganese, copper, chromium and / or silicon, thereby further optimizing the matrix of the wear-resistant protective layer in terms of its ductility, hardness, chemical resistance, processability, friction properties, temperature resistance and adhesion resistance.

[0045] In this regard, it is advantageous if, during the heat application of the particles, 50% or less of the particles bounce off the matrix and / or the already applied wear-resistant protective layer, preferably 40% or less, or 25% or less, and particularly preferably 20% or less.

[0046] Therefore, it is possible to ensure an advantageous improvement in efficiency compared to this method.

[0047] In the sense of the present invention, favorable adhesion of particles to the work roll can be achieved only when the particle mixture containing hard phase particles and matrix particles has a residual moisture content of less than or equal to 10%, preferably less than or equal to 5%, and particularly preferably less than or equal to 2%.

[0048] In the context of this invention, the term "residual moisture" should be understood as the amount of moisture, particularly water, bound to the particulate mixture.

[0049] The residual moisture is measured before adding the particles or a mixture of particles to the hot gas stream of the application device.

[0050] If the residual moisture content is above the aforementioned value, it is advantageous to reduce the residual moisture content to less than or equal to 10%, preferably less than or equal to 5%, and particularly preferably less than or equal to 2% before adding the particles to the hot gas stream.

[0051] In this respect, it is advantageous to manipulate this method, and especially other method parameters, based on the residual moisture content of the particulate mixture.

[0052] For example, the outlet temperature of the hot gas stream discharged from the outlet nozzle of the application device along with the particles can be manipulated based on the residual moisture, to give just one example.

[0053] Furthermore, lower residual moisture can result in a more uniform particle mixture, particularly regarding the distribution of moisture within the particle mixture, thereby improving the adhesion of the particles to the matrix and / or the abrasion-resistant protective layer.

[0054] In this respect, residual moisture can ensure an advantageous increase in efficiency relative to this method.

[0055] If the particles have a particle size greater than or equal to 0.5µm, preferably greater than or equal to 1µm, and / or less than or equal to 60µm, preferably less than or equal to 30µm, and particularly preferably less than or equal to 15µm, the beneficial adhesion between the particles and the work roller can also be improved individually or cumulatively in the sense of the present invention.

[0056] In the context of this invention, the term "particle size" refers to the average powder diameter of a powder composed of particles, which provides the starting material for the wear-resistant protective layer.

[0057] For example, the smaller the particle size or average powder diameter, the lower the exit velocity (particle velocity) of the hot gas flow at the outlet nozzle of the application device can typically be selected. On the other hand, by utilizing a smaller particle size, the outlet temperature level at the outlet nozzle of the application device can be manipulated.

[0058] This also affects application efficiency, as smaller particles have been found to increase the average adhesion or adhesion capacity of the particles on the application roller (with constant heat transfer).

[0059] In this respect, the degree of adhesion between the particles and the working roller can be affected simply by selecting the particle size.

[0060] In this respect, the efficiency can be improved advantageously relative to this method by means of powder size.

[0061] The table below provides further favorable interactions with respect to particle size.

[0062]

[0063] Figure 1: Particle size (µm) of powdered granular mixture: roughness of the wear-resistant protective layer, roughness of the product (strip) processed by the work roll, residual stress in the wear-resistant protective layer and / or matrix, porosity, hardness, peak number, uniformity, especially the uniformity of the distribution of coating elements within the wear-resistant protective layer and the uniformity of the thickness of the wear-resistant protective layer, (coating) element distribution, anti-adhesion tensile properties, anti-delamination and spread width (evaluation in each case is between 0 and 10, with a single scale between the minimum possible (0) and the maximum possible (10) (scale name: kg) and the neutral (0) and the best possible (10) (scale name: nb).

[0064] In order to reliably ensure this advantageous particle size on the application device, it is advantageous if the particles are pre-screened to a particle size of less than or equal to 60 µm, preferably less than or equal to 30 µm, and particularly preferably less than or equal to 15 µm.

[0065] The spread width of powdered granular mixtures can also be advantageously influenced by the proposed particle size, particularly by reducing it.

[0066] More precisely, as particle size increases, the spreading width of the particles impacting the work roller can be reduced.

[0067] It has been shown that using smaller particle sizes can achieve higher levels of (compressive) residual stress in the wear-resistant protective layer, which can at least indirectly lead to favorable effects on the wear-resistant protective layer's resistance to adhesive tensile stress and / or delamination. Furthermore, or according to the foregoing, smaller particle sizes can contribute to lower porosity in the wear-resistant protective layer, thereby further improving its resistance to delamination.

[0068] Furthermore, if particles or particle mixtures are pre-screened in the sense of this invention, unwanted impurities can be effectively removed in advance.

[0069] Furthermore, the proposed pre-screening method can achieve higher uniformity of the powdered particle mixture, resulting in a correspondingly good uniformity of the wear-resistant protective layer.

[0070] Overall, pre-screening can ensure a more stable application process.

[0071] To provide suitable starting materials, for example, for producing different abrasion-resistant protective layers for different work rolls used on the application device, it is advantageous if the particles are pre-screened on the application device, especially before being added to the hot gas flow of the application device.

[0072] By pre-screening starting materials or particles for this purpose, this method can be used to more specifically set the parameters of particle mixtures.

[0073] If the particles at or behind the outlet nozzle of the application device have an outlet velocity of 500 m / s or greater, preferably 800 m / s or greater, particularly preferably 900 m / s or greater, and / or have an outlet velocity of 1500 m / s or less, preferably 1200 m / s or less, particularly preferably 1000 m / s or less, this can also positively influence the adhesion of the particles to the work roller in the sense of the present invention.

[0074] If a lower exit speed is selected, the particles may not bond tightly to each other, to the matrix, and / or to the wear-resistant protective layer that already exists on the matrix when they impact the work roll. As a result, the porosity and / or permeability of the wear-resistant protective layer may increase in particular.

[0075] On the other hand, if a higher exit speed is chosen, the level of residual compressive stress generated in the wear-resistant protective layer can be increased, which can advantageously increase the anti-adhesion tensile properties of the wear-resistant protective layer. However, the risk of particles bouncing into the surrounding environment and being lost in the process of impacting the work roll continues to increase, which may result in a decrease in application efficiency.

[0076] In other words, this means that the inherent kinetic energy of the particles when they hit the application roller can also be affected by manipulating the exit speed, which in turn affects the clamping of the particles on the application roller.

[0077] For example, a higher exit speed can improve the application efficiency of particles on the application roller, because higher kinetic energy generally leads to better particle adhesion.

[0078] For example, exit speed also affects particle temperature, because a higher exit speed reduces the contact time with the burner flame, which in turn can lower the temperature of the particles when they hit the work roll.

[0079] If the exit velocity is measured at a location or area 100 mm or less, preferably 50 mm or less, and particularly preferably 10 mm or less from the exit nozzle, the exit velocity can be measured in a particularly reliable and reproducible manner.

[0080] For example, this can reduce the risk that measurements of environmental impact may be severely compromised, as the adhesion conditions of particles to the work roll may be negatively affected by falsified measurements.

[0081] For example, if the outlet velocity of the hot gas flow is set according to the particle characteristics, the adhesion ability can be easily manipulated.

[0082] In this respect, the adhesion of particles to the working roll in the sense of this invention can also be achieved or cumulatively improved simply by a favorable selection of the exit speed, as suggested herein.

[0083] Cumulatively or alternatively, if particles are discharged from the outlet nozzle of the application device by means of a hot air stream, wherein the particles and / or the hot air stream have an outlet temperature of greater than or equal to 800°C, preferably greater than or equal to 1000°C, particularly preferably greater than or equal to 1200°C, and / or the particles and / or the hot air stream have an outlet temperature of less than or equal to 2200°C, preferably less than or equal to 2000°C, particularly preferably less than or equal to 1800°C, the adhesion ability of the particles on the work roller can also be adjusted.

[0084] For example, the particles are heated in a hot gas stream and are in this case melted or liquefied, the degree of which is particularly dependent on the particle size.

[0085] In general, this can also regulate the adhesion ability of particles.

[0086] The quality of the wear-resistant protective layer will also be affected as a result.

[0087] The outlet temperature can be adjusted, for example, based on residual moisture and / or particle size.

[0088] In this regard, it is advantageous to adjust the outlet temperature according to the characteristics of the particles.

[0089] Therefore, when residual moisture is high, choosing a higher outlet temperature may be advantageous.

[0090] For example, if a smaller particle size is selected, the outlet temperature can also be set lower.

[0091] If the outlet temperature is measured at a location or area 100 mm or less, preferably 50 mm or less, and particularly preferably 10 mm or less from the outlet nozzle, a particularly meaningful value for the outlet temperature can be measured.

[0092] Experiments show that the outlet temperature of particles and / or hot gas flow can be advantageously measured at a distance between 5 mm and 15 mm behind the outlet nozzle.

[0093] Another very advantageous variation of the method can be provided if, during the application of particles to the work roll, an excess of the coating, including particles, process gases, combustion products, etc., which do not adhere to the substrate, is drawn from the surrounding environment of the work roll at a suction speed of greater than or equal to 10 m / s, preferably greater than or equal to 15 m / s, particularly preferably greater than or equal to 18 m / s, and / or at a suction speed of less than or equal to 30 m / s, preferably less than or equal to 25 m / s, particularly preferably less than or equal to 20 m / s, surrounding the work roll.

[0094] This suction method can also prevent unwanted particle loss.

[0095] On the one hand, if the interfering elements associated with this are removed from the immediate surroundings of the work roll, especially after contact with the work roll, the degree of overspraying around the key work roll can be advantageously reduced.

[0096] Such interfering elements may include, for example, excessive particles, process gases, combustion products, etc., and if they cannot be adequately removed due to the corresponding impurities or defects, they can lead to quality problems on the wear-resistant protective layer.

[0097] On the other hand, by using the suction speed selected within the recommended range, it is possible to prevent particles that have not yet come into contact with the work roll from deviating unfavorably from their intended trajectory, thus missing their target on the work roll, or even just adversely impacting the work roll.

[0098] Therefore, in the sense of this invention, the adhesion between particles and the working roller can be improved individually or cumulatively. Furthermore, this also allows for an improved layer quality of the wear-resistant protective layer.

[0099] Furthermore, if it is for the purpose of suctioning excess spray, it is advantageous for at least one suction opening of the suction device to be arranged at a distance of greater than or equal to 0.1 m, preferably greater than or equal to 0.2 m, and / or at a distance of less than or equal to 1.5 m, preferably less than or equal to 1 m, and particularly preferably less than or equal to 0.5 m relative to the work roller.

[0100] Due to the distance presented here, excess coating can be removed from the work roll or its surroundings in an operationally reliable manner.

[0101] In this case, at least one suction opening is preferably arranged on the side of the work roll opposite to the discharge nozzle, so that particles flowing through or rebounding from the work roll can be directly sucked from the surrounding environment of the work roll.

[0102] Alternatively or cumulatively, other or additional locations may be provided for arranging at least one or more suction openings.

[0103] It is advantageous to adjust the distance between the work roller and the suction opening according to the suction speed.

[0104] Therefore, the dangers of air movement or air turbulence that have a negative impact on the immediate surrounding environment of the work roll can be avoided or at least significantly reduced.

[0105] The suction speed or suction distance can also result in additional cooling effects relative to the work roll, for example, by means of the airflow generated by suction, which can flow along the surface of the work roll, especially its substrate or wear-resistant protective layer.

[0106] In particular, the distance between the suction opening and the working roller can also be positioned according to the available suction capacity in order to further manipulate the temperature during the heat application of the particles.

[0107] For example, adjusting the suction speed and / or the distance between the matrix and the suction opening based on the exit speed of the particles at or behind the outlet nozzle of the application device can have a positive impact on the adhesion ability of the particles.

[0108] The coating temperature can also be affected as a result.

[0109] In the context of this invention, favorable adhesion between particles and the working roller can be achieved or cumulatively improved solely by means of the suction described herein, as suggested herein.

[0110] Therefore, this method can also be operated more efficiently.

[0111] Furthermore, it is advantageous if, for a particle mixture comprising hard phase particles and matrix particles, the hard phase proportion is set to be greater than or equal to 50%, preferably greater than or equal to 55%, particularly preferably greater than or equal to 60%, and / or less than or equal to 90%, preferably less than or equal to 85%, particularly preferably less than or equal to 80%.

[0112]

[0113] Figure 2: Ratio of hard phase in particulate mixture, i.e., ratio of hard phase to total layer system consisting of hard phase and matrix: hardness, roughness Ra, density, uniformity of elemental distribution, uniformity of layer thickness distribution, peak number, anti-adhesion tensile strength, residual stress and porosity of each wear-resistant protective layer (evaluation in each case is between 0 and 10, with individual scales between minimum possible (0) and maximum possible (10) (scale name: kg) and neutral (0) and best possible (10) (scale name: nb).

[0114] In particular, this hard phase ratio can advantageously affect the hardness of the wear-resistant protective layer.

[0115] In this regard, it is advantageous if the proportion of the hard phase in the particulate mixture as a whole has the value described above.

[0116] Other beneficial interactions in this regard can be found in the table below.

[0117] If the substrate is preheated to a substrate temperature of 30°C or higher, preferably 50°C or higher, particularly preferably 60°C or higher, and / or less than or equal to 120°C, preferably less than or equal to 150°C or higher, particularly preferably less than or equal to 200°C, then further advantageous adhesion between the particles and the work roller can be achieved or cumulatively improved in the sense of the present invention.

[0118] In particular, by means of this preheating of the substrate, a favorable increase in the adhesion of the wear-resistant protective layer on the substrate relative to the work roll can be achieved, and in this respect, the layer quality can also be improved.

[0119] It has been found that improved layer quality can also be achieved using a matrix with higher temperatures.

[0120] In particular, the stress state in the wear-resistant protective layer can be advantageously influenced by the heated substrate.

[0121] In addition, by preheating the substrate, residual moisture that may be present in the substrate, especially adsorbed water and / or gases deposited on the substrate, can be reduced and / or minimized.

[0122] The wear-resistant protective layer applied by the method described herein can already be used on work rolls, wherein, after actual application, the wear-resistant protective layer can also be further processed as needed, for example by means of abrasive and / or subtractive manufacturing processes.

[0123] In the context of this invention, if the substrate or the wear-resistant protective layer already disposed thereon is processed by abrasive and / or subtractive processing before and / or during the application of particles to the work roll, the adhesion of the particles can generally be improved at least locally.

[0124] In particular, this allows used work rolls to be well processed or repaired.

[0125] If the abrasion-resistant protective layer is at least partially and / or partially removed before and / or during the application of particles to the work roll, this is particularly advantageous for repair.

[0126] As a result, the adhesion of particles to the wear-resistant protective layer can be significantly improved, and the wear-resistant protective layer is already present on the substrate of the used work roll.

[0127] This is particularly applicable when an old wear-resistant protective layer, already arranged on the substrate, is processed using a subtractive process before the particles are applied to the processed old wear-resistant protective layer.

[0128] If the wear-resistant protective layer is post-processed, especially with the help of the EDT (electrode texturing) method, additional processing of the wear-resistant protective layer can be achieved.

[0129] By combining this post-processing method, it is easy to generate customized requirements for the wear-resistant protective layer of the work roll, especially the customized requirements for the texture of the wear-resistant protective layer of the work roll.

[0130] Furthermore, if the substrate is provided in a semi-automatic or automatic manner, the application method can be further developed advantageously.

[0131] With the help of automation in this area, the process can be controlled more precisely and executed in a better coordinated manner. As a result, the adhesion of particles to the working rollers can also be beneficially affected.

[0132] In the case of semi-automatic method variations, manual intervention by the operator may still be required during or after the method steps, while in the case of fully automatic method variations, such manual intervention is not absolutely necessary.

[0133] If the substrate is automatically measured and the actual value is determined therefor, in particular, the determined actual value is compared with the set value, then in the sense of the present invention, the wear-resistant protective layer to be applied to the application roller can be applied to the application roller more accurately by means of this application method.

[0134] The proposed measurements can be performed at different times in conjunction with the proposed methods, particularly before, during and / or after the substrate is provided to the application device.

[0135] Furthermore, it is advantageous to automatically determine at least one coating parameter based on the determined actual value.

[0136] In particular, in the sense of this invention, the coating parameters already explained above can be determined at least partially automatically.

[0137] In this way, advantageous adhesion of particles to the working roller in the sense of this invention can be achieved.

[0138] By incorporating the proposed method, coating parameters can be determined at different points in time, particularly before, during, and / or after the application of particles to the substrate on the application device.

[0139] As described above, if the substrate is automatically preheated according to a determined actual value, particularly to one of the aforementioned substrate temperatures, the adhesion of particles to the work roll can be advantageously affected in the sense of this invention.

[0140] The degree of automation can be further developed if the wear-resistant protective layer applied to the substrate is automatically re-inspected, especially optically.

[0141] Therefore, the quality of the manufactured work rolls can be controlled more easily, quickly, and reliably.

[0142] If the manufactured work rolls are automatically identified and recorded, for example by means of barcodes, RFID chips, etc., then specific data about the manufactured work rolls can be reliably assigned to the manufactured work rolls.

[0143] If recovery samples are generated automatically, this method can further improve quality assurance.

[0144] Alternatively, the new wear-resistant protective layer applied to the substrate is processed by subtractive processing methods, particularly post-processing, especially by abrasives and / or by means of selective laser melting.

[0145] The tip of the applied wear-resistant protective layer is preferably broken at its tip by an abrasive process, particularly by grinding, and / or the tip of the wear-resistant protective layer is rounded by selective laser melting.

[0146] Therefore, when using work rolls, especially when rolling metal products, it is advantageous to achieve less material removal of the wear-resistant protective layer, resulting in an increased service life of the wear-resistant protective layer and reduced contamination of the rolled strip by the removed wear-resistant protective layer.

[0147] Furthermore, when coated products, especially galvanized metal products, are rolled with work rolls, less coating is transferred to the work rolls, resulting in increased service life of the wear-resistant protective layer and improved quality of the rolled strip.

[0148] According to a second aspect, the object of the present invention is to provide a work roll comprising a substrate and a wear-resistant protective layer for rolling metal articles, particularly for rolling metal strips, wherein the work roll is manufactured by a method according to one of the features described herein.

[0149] With the aid of rollers manufactured in the sense of this invention, high-quality mechanical treatment can be performed on metal products, especially their surfaces.

[0150] Furthermore, work rolls manufactured or repaired using this method typically have a longer service life.

[0151] According to a third aspect, the object of the invention is also achieved by a rolling mill stand for processing metal products such as metal strips, including work rolls with one of the features described herein.

[0152] Because the rolling mill stand is equipped with this work roll, the setup work can be further reduced or the setup interval can be further extended.

[0153] This is especially true because the work rolls have an increased service life, allowing them to be used on the rolling stand for a longer period of time.

[0154] According to the fourth aspect, the object of the present invention is also achieved by a metal strip, wherein the metal strip is rolled with the work roll, particularly by cold rolling.

[0155] Based on the surface images obtained on the metal strip, certain features of the wear-resistant protective layer can be advantageously identified.

[0156] In particular, when rolling metal strip, the texture of the wear-resistant protective layer of the work roll can be transferred from the surface of the work roll, especially the surface of the wear-resistant protective layer, to the surface of the metal strip.

[0157] By using this work roll to process metal strips, very high-quality metal strips can be manufactured.

[0158] According to a fifth aspect of the invention, this objective is achieved by an application device for applying particles to a substrate of a work roll, particularly a hot application device, comprising a burner device, particularly an HVOF burner (high-speed oxygen fuel burner) and / or an HVAF burner (high-speed air fuel burner) and / or the like, wherein the application device is configured such that during the hot application of particles to the work roll, 50% or more of the particles remain adhered to the substrate and / or the applied abrasion-resistant protective layer, and remain on the substrate and / or the abrasion-resistant protective layer.

[0159] Using this application device, at least about 50% of the particles adhere to the substrate or its wear-resistant protective layer and are not lost.

[0160] In this respect, the application device is particularly effective in the manufacture and repair of work rolls or wear-resistant protective layers for this purpose.

[0161] It is particularly advantageous if the application device is configured such that 60% or more of the particles remain adhered to the substrate and / or the applied abrasion-resistant protective layer, preferably 75% or more, and especially preferably 80% or more.

[0162] As a result, the application device can be operated particularly effectively.

[0163] In particular, this application device can significantly improve the method of applying particles to a substrate to produce a wear-resistant protective layer for work rolls or to repair such a wear-resistant protective layer.

[0164] Preferably, the application device is configured such that during the application of heat to the particles onto the work roll, 40% or less of the particles rebound from the matrix and / or the already applied abrasion-resistant protective layer, preferably 25% or less, particularly preferably 20% or less, thus allowing the application device to operate extremely efficiently. In particular, this method enables a particularly resource-efficient approach.

[0165] If the application apparatus includes a detection device for detecting residual moisture in a particle mixture comprising hard phase particles and matrix particles, wherein the detection device has one or more sensor elements, the efficiency described herein can be advantageously achieved using this application apparatus.

[0166] If at least one sensor element is arranged on the feeding device for providing the particle mixture, it is advantageous to check the residual moisture of the particles on the feeding device by means of the detection device of the feeding device.

[0167] If the equipment provided includes powder conveyors, powder mixers, etc., then it is advantageous to provide such equipment.

[0168] Cumulatively or alternatively, it is advantageous if the applying device has a screening device for screening particles according to their particle size, wherein the screening device has one or more screening elements.

[0169] For example, different particles can be pre-screened on the application device simultaneously or continuously by means of several screening elements, especially according to different particle sizes and particle materials.

[0170] In this regard, with the help of screening equipment, particles can be pre-screened on the application device as needed.

[0171] It should be understood that suitable screening equipment can be designed in different ways and can be provided on the application device.

[0172] If the screening equipment is arranged on the feeding equipment used to provide particles, such as a powder conveyor, powder mixer, etc., the screening equipment can be implemented in a simple and compact structure on the application device.

[0173] The efficiency of this application device can also be advantageously achieved or improved by means of the screening equipment described herein.

[0174] If the application device includes another detection device for detecting particle size, wherein the other detection device has one or more sensor elements, the application device can also be advantageously constructed.

[0175] Furthermore, by means of another detection device of the application device, the efficiency of this application device can be advantageously achieved or further improved.

[0176] Sensor elements can also be implemented and placed on the application device in different ways.

[0177] An advantageous embodiment provides at least one sensor element of another detection device arranged on a feeding device for providing particles, wherein the feeding device may include a powder conveyor, a powder mixer, etc.

[0178] Furthermore, in the context of this invention, the efficiency of the application device can also be achieved or further improved if the application device includes a measuring device for measuring the exit velocity of the particles at the exit nozzle, wherein the measuring device has one or more sensor elements.

[0179] Advantageously, one or more sensor elements are configured to measure the exit velocity at or behind the exit nozzle.

[0180] For this purpose, one or more sensor elements can be arranged at or behind the outlet nozzle.

[0181] Furthermore, it is advantageous if the applying device has another measuring device for measuring the outlet temperature of the particles at the outlet nozzle, wherein the other measuring device has one or more sensor elements.

[0182] In this way, the efficiency of the application device in the sense of the present invention can also be well achieved or further improved.

[0183] Furthermore, if one or more sensor elements are configured to measure the outlet temperature at or behind the outlet nozzle, the outlet temperature can be measured reliably.

[0184] Therefore, at least one sensor element can be arranged at or behind the outlet nozzle.

[0185] If the application device has a suction device for drawing out excess spray from the surrounding environment of the substrate, including particles, process gases, combustion products, etc. that do not adhere to the substrate, wherein the suction device has one or more suction elements with suction openings, the efficiency to be achieved in the sense of the present invention can also be achieved.

[0186] This suction device can be constructed and arranged differently on the application device.

[0187] If the suction element can be flexibly positioned relative to the working roller, the suction device can be advantageously configured to handle the specific particles.

[0188] In this respect, it is advantageous if the suction element or its suction opening is adjustable with respect to its position relative to the work roller.

[0189] In this regard, it is particularly advantageous if the suction equipment includes another detection device for detecting the position of one or more suction elements relative to the work roller.

[0190] If one or more suction elements are arranged on the side opposite to the outlet nozzle of the application device relative to the application roller, excess coating can be removed from the surrounding environment of the work roller in a particularly effective manner.

[0191] If the application apparatus includes a mixing device for mixing particles with hard phase particles and matrix particles, wherein the mixing device has another measuring device for measuring the proportion of hard phase and / or matrix, wherein the other measuring device has one or more sensor elements, then the application apparatus can achieve advantageous efficiency cumulatively or alternatively.

[0192] Another measuring device of the application device can be advantageously arranged on the mixing equipment and / or the feeding equipment for providing particles, such as a powder conveyor.

[0193] If the applying device has a machining apparatus for abrasive or subtractive processing, it is advantageous to process the substrate and / or wear-resistant protective layer, especially before and / or after applying the wear-resistant protective layer.

[0194] The efficiency of this application device can also be advantageously obtained or improved because the application device is equipped with a processing device for abrasive or subtractive work, which allows the substrate or the wear-resistant protective layer already present thereon to be better prepared for the application of particles.

[0195] Furthermore, the new wear-resistant protective layer applied to the substrate can be post-processed using a subtractive processing apparatus, particularly an abrasive subtractive processing apparatus and / or a subtractive processing apparatus with a device for selective laser melting.

[0196] If the application device has a supply device for supplying the substrate to the processing position, a rotation device for rotating the substrate at the processing position, and / or a removal device for removing the work roller from the processing position, wherein the supply device, rotation device, and removal device operate in a semi-automatic or preferably fully automatic manner, a high degree of automation can be achieved in this application device, and thus high efficiency can also be ensured.

[0197] It is also advantageous if the application device has cooling and / or cleaning equipment, wherein the cooling and / or cleaning equipment has one or more nozzle elements with nozzle openings.

[0198] The efficiency in terms of adhesion can be significantly improved solely due to the cooling and / or cleaning effects that can be achieved on the application roller.

[0199] Advantageously, one or more nozzle elements and their nozzle openings are adjustable with respect to their position relative to the working roll, such that different cooling effects can be achieved on the working roll, for example, depending on the outlet temperature of the hot gas stream carrying the particles.

[0200] For example, cooling or cleaning equipment is equipped with two to four nozzle elements, which can also be positioned differently in space relative to the work roller by means of a robotic arm.

[0201] It is advantageous if the distance between the work roller and the nozzle element or its nozzle opening is greater than or equal to 2 mm, preferably greater than or equal to 5 mm, particularly preferably greater than or equal to 10 mm, and / or less than or equal to 250 mm, preferably less than or equal to 150 mm, particularly preferably less than or equal to 100 mm.

[0202] This distance can also be specifically set according to the characteristics of the substrate of the corresponding work roll, such as size and mass.

[0203] Additional cooling effects relative to the work roll can also be achieved by varying the distance, for example by an airflow that acts more or less strongly on the work roll, which can flow along the surface of the work roll, especially relative to its substrate or wear-resistant protective layer.

[0204] In particular, the distance between the nozzle opening and the working roller can also be positioned according to the available cooling capacity in order to further manipulate the temperature during the heat application of the particles.

[0205] Generally, for the vast majority of applications, a distance between 15mm and 50mm has proven to be very suitable.

[0206] In this case, a smaller distance has a greater impact on particle deflection, while a larger distance usually results in a greater reduction in cooling effect relative to the work roll.

[0207] In particular, cooling options have proven advantageous in this context, especially with regard to smaller work rolls, as these work rolls reach critical heating more quickly than larger work rolls during thermal spraying.

[0208] If the work roll is adequately cooled, the risk of having to interrupt the application process due to overheating of the work roll can be reduced.

[0209] In general, better cooling of the work rolls allows for more consistent process control, which in turn leads to a higher quality layer structure for the wear-resistant protective layer.

[0210] Typically, interruptions reduce the cost-effectiveness of this method.

[0211] Various media can be used as cleaning agents, especially coolants. However, CO2 has proven to be very advantageous, particularly for smaller work rolls.

[0212] In any case, by means of cooling and / or cleaning equipment and by means of further method variations of the wear-resistant protective layer with respect to the cleaning substrate and / or optional abrasive pretreatment, the adhesion of particles to the work roll can be advantageously improved, thereby also improving the efficiency of the method or the application device.

[0213] This similarly applies to cooling the substrate using cooling and / or cleaning equipment. If the work roll is cooled using this method, the ability of particles to adhere to the work roll can also be advantageously improved, thus increasing the efficiency of the method or the application apparatus.

[0214] In order to ensure a uniform supply of granules on the application device, it is advantageous if the application device includes a feeding device for supplying granules, wherein the feeding device is configured to supply granules with a feeding tolerance of + / - 2 g / min relative to the feeding rate.

[0215] As mentioned above, if it is advantageous for the application device to have one or more providing devices, various detection and / or measuring devices may also be arranged thereon.

[0216] In order to make uniform amounts of particles usable for heat application or spraying, especially at the outlet nozzle of the application device, it is absolutely necessary to reliably deliver the particles.

[0217] In this regard, a maximum feed tolerance of + / - 2 g / min has proven advantageous in order to produce a particularly uniform abrasion-resistant protective layer on the work roll.

[0218] Depending on the amount of particles to be effectively conveyed, the conveying tolerance can vary upwards or downwards.

[0219] In particular, the equipment can be configured as a powder conveyor with appropriate settings for conveying mixtures of powdery particles.

[0220] It should be understood that the various devices of the application apparatus, such as, in particular, detection devices, measuring devices, cooling and / or cleaning devices and / or screening devices, can be manually set onto the corresponding work rollers.

[0221] However, it is advantageous if the relevant equipment can be set automatically, for example, based on process parameters, such as data about the substrate and / or wear-resistant protective layer.

[0222] Furthermore, it is advantageous if the equipment, particularly the powder conveyor, is configured to preheat the particles or mixture of particles to be conveyed using the heat generated at the application device (e.g., an HVOF burner or an HVAF burner).

[0223] For example, the melting behavior or liquefaction of particles in a hot gas flow can be influenced by this preheating of the particles.

[0224] In this regard, it should also be mentioned that it is advantageous if the heat energy generated by the application device is also cumulatively used to reduce the residual moisture on the particulate mixture.

[0225] It is also advantageous that the heat generated by the application device is cumulatively used to preheat the substrate of the work roll.

[0226] However, a preferred embodiment provides that the application device has control and / or regulation equipment, wherein the control and / or regulation equipment is configured to automatically control or regulate one or more devices of the application device, and in particular, they are also interdependent.

[0227] With the aid of such control and / or regulation devices, the operation of one or more devices can be automatically controlled, thereby further advantageously influencing adhesion.

[0228] In this respect, it is advantageous if the control and / or regulation equipment relies particularly on the operation of at least one of the detection devices, at least one of the measuring devices, cooling and / or cleaning devices, screening devices and / or other providing devices, supplying devices, rotating devices and / or removing devices, etc., and especially on the data determined thereon.

[0229] Clearly, the efficiency of this application device can be advantageously achieved or further improved by means of appropriately configured control and / or adjustment equipment.

[0230] Therefore, it is particularly advantageous if the control and / or regulation equipment is configured such that 50% or more of the particles remain adhered to the substrate and / or the applied abrasion-resistant protective layer during the application of heat to the work roll.

[0231] It is particularly advantageous if the control and / or regulation device is configured such that 60% or more of the particles remain adhered to the substrate and / or the applied abrasion-resistant protective layer, preferably 75% or more, and especially preferably 80% or more.

[0232] If the control and / or adjustment equipment is set such that 40% or less of the particles bounce off the matrix and / or the already applied abrasion-resistant protective layer during the application of heat to the work roll, preferably 25% or less, particularly preferably 20% or less, the application device can operate particularly effectively.

[0233] In this regard, control and / or regulation equipment for controlling and / or regulating the application device is advantageous, particularly for methods that perform one of the features described herein.

[0234] In particular, the method according to the invention can be performed particularly effectively by an application device operated in this manner.

[0235] Further beneficial efficiency improvements regarding the adhesion ability of particles to the working roller can also be achieved by selecting the size (dimensions) of the working roller, the mass of the working roller, the matrix material and / or the manufacturing method of the matrix.

[0236] Preferably, the application device has a layer thickness control device configured to measure the layer thickness of the wear-resistant protective layer, particularly a layer thickness control device that operates in real time, and particularly a layer thickness control device that operates permanently.

[0237] In this way, the application device can be advantageously controlled and / or adjusted to achieve the desired thickness of the wear-resistant protective layer.

[0238] Other advantages, details and features of the invention also arise from the embodiments explained below.

[0239] In the attached diagram:

[0240] Figure 1 A schematic view illustrates a possible sequence of methods for manufacturing or repairing work rolls, with several method options, some of which are optional; and

[0241] Figure 2 A schematic view of an application device for applying particles onto a work roll is shown, by means of which the following actions can be performed. Figure 1 Methods or sequence of methods.

[0242] according to Figure 1 The illustration, as an example, shows a work roll 100 for rolling metal products (not shown) (see Figure 100). Figure 2 The first possible method sequence I for the automatic manufacturing or repair of )

[0243] At this point, it should be mentioned that the method modifications for this purpose are not shown or described separately again through other diagrams in the method sequence.

[0244] In this regard, the order of individual method steps can be changed, or they can be combined with each other.

[0245] It should also be understood that, on the one hand, individual method steps may be optional, and on the other hand, the method sequence shown only as an example may be supplemented by further method steps or modifications thereof not explicitly shown herein.

[0246] according to Figure 1 The exemplary method shown in the figure begins at point 1 and has a first method step 1, which includes providing a substrate 102 for a work roller 100.

[0247] This could be a work roll 100 to be newly manufactured with an unused substrate 102, or a work roll 100 to be repaired with a used substrate 2 having a used wear-resistant protective layer 104.

[0248] In any case, the work roller 100 can be automatically applied from the starting point 1 to the application device 110 for heat-applying or spraying particles 112 onto the surface 104 of the work roller 100 (see application device 110). Figure 2 This means that no manual intervention from operators is required.

[0249] Using the sequence of methods shown and explained here, 65% or more of the particles 112 sprayed in the direction of the work roll 100 will adhere to the work roll 100, resulting in the method being able to operate extremely efficiently.

[0250] After the substrate 102 is prepared or supplied to the processing position 116 of the application device 110, the substrate 102 is cleaned according to method step 2.

[0251] According to step 3 of the method, the substrate 102 is measured to determine the actual values ​​of the substrate 102 and the old wear-resistant protective layer 104 that may already exist on it.

[0252] According to step 4 of the method, the determined actual value can be automatically compared with the set value.

[0253] According to step 5 of the method, the processing and coating parameters can then be automatically determined based on the actual values.

[0254] According to step 6 of the method, if necessary, the substrate 102 can be automatically preheated, for example, to 110°C.

[0255] If this is the work roll 100 to be repaired, then according to intermediate method step 6A, the existing old wear-resistant protective layer 104 can first be subjected to abrasive treatment, especially in an automatic manner, so as to perform partial layer removal in an automatic manner, so that the old wear-resistant protective layer 104 is automatically homogenized and processed as a whole, or, if necessary, completely removed from the substrate 102 in an automatic manner.

[0256] Subsequently, if necessary, the substrate 102 to be processed can be preheated according to step 6 of the method.

[0257] According to step 7 of the method, the residual moisture is automatically measured and, if necessary, automatically reduced to a value of 7%.

[0258] According to step 8 of the method, particle 112 can be automatically preheated.

[0259] According to step 9 of the method, particles 112 are automatically pre-screened so that different particles have particle sizes between 10µm and 25µm.

[0260] According to step 10 of the method, particles 112 are automatically mixed to form the desired particle mixture 112A, which is composed of hard phase particles and matrix particles, wherein the proportion of hard phase is 65%.

[0261] According to step 11 of the method, the particulate mixture 112A is automatically preheated to an operating temperature, for example, which can be set to approximately 60 °C.

[0262] According to step 12 of the method, the particles 112 are automatically heat-applied or sprayed as a particle mixture 112A onto the work roller 100 rotating at the processing position 116, for example having an adhesion capacity of more than 65%.

[0263] According to step 13 of the method, the exit velocity of the particulate mixture 112A discharged from the outlet nozzle 122 of the application device 110 in the hot gas flow 120 is automatically measured and, if necessary, automatically adjusted, for example, to about 1050 m / s.

[0264] According to step 14 of the method, the outlet temperature of the particulate mixture 112A is automatically measured and, if necessary, automatically adjusted, for example, to approximately 900°C.

[0265] According to step 15, the excess coating 126 is automatically drawn from the surrounding environment 130 of the work roller 100, preferably at a suction speed of 22 m / s.

[0266] According to step 16 of the method, the work roll 100 is automatically cooled.

[0267] According to method step 17, the wear-resistant protective layer 104 is post-processed automatically, for example by means of the EDT method.

[0268] According to method step 18, the wear-resistant protective layer 104 is automatically re-inspected, for example, optically.

[0269] According to step 19 of the method, the manufactured work roll 100 is automatically identified and recorded.

[0270] According to step 20 of the method, the recovery sample is automatically generated.

[0271] According to step 21 of the method, the manufactured work roll 100 is automatically removed from the processing position and ready for further use.

[0272] In this regard, the method sequence, explained by way of example, starting from point 1, ends with method step 21, which represents the endpoint 21 of the method sequence.

[0273] Now, the method sequence can restart from starting point 1, where the method sequence can occur in the same or different ways.

[0274] As mentioned above, individual method steps can be combined, repeated, or optionally performed or omitted in almost any way.

[0275] according to Figure 2The illustration now shows a first possible embodiment of an application device 110 for applying particles 112 as a particle mixture 112A to the surface 102A of the substrate 102 of the work roller 100.

[0276] In this case, the application device 110 has a machine orientation 132, in which the particulate mixture 112A is applied to the work roller 100.

[0277] The application device 110 has a processing position 116, where a work roller 100 for applying hot particles 112 is rotatably supported by a rotating device 136 about a rotation axis 136A. Figure 2 The diagram shows the rotation direction 136B.

[0278] The application device 110 has a supply device 138 (shown schematically only) having a supply position 138A, from which the substrate 102 of the designated work roller 100 is supplied from the supply position 138A along the supply direction 138B to the processing position 116.

[0279] The application device 110 also has a removal device 140 (shown schematically only) having a removal position 140A, into which the manufactured work roller 100 is removed from the processing position 116 along the removal direction 140B.

[0280] In this embodiment, the application device 110 also includes a processing device 144 (shown schematically only) for abrasive and / or subtractive processing, by means of which the substrate 102 and / or wear-resistant protective layer 104 can be processed as needed.

[0281] In order to generate the hot gas flow 120, the application device 110 has a burner device 146, wherein the particles 112 are discharged from the outlet nozzle 122 of the application device 110 in the machine direction 132 by means of the hot gas flow 120.

[0282] The burner device 146 can be designed in different ways, for example as an HVOF burner.

[0283] In order to reliably supply the granules 112 or the powdered granule mixture 112A to the burner device 146 and provide it adequately there, the application device 110 has a supply device 150.

[0284] In this configuration, the providing device 150 is positioned to be effectively connected to the burner device 146, particularly above the burner device 146, and specifically includes a powder conveying device 150A for conveying particles 112 or particle mixture 112A, a mixing device 150B for mixing particles 112 or particle mixture 112A, and a screening device 150C for screening particles 112 or particle mixture 112A.

[0285] In order to set the best possible residual moisture for the particles 112 and the powdered particle mixture 112A before the particles 112 are supplied to the burner device 146 or its outlet nozzle 122, the application device 110 has a first detection device 152 whose sensor element (not shown here) can detect the residual moisture of the particles 112 and the powdered particle mixture 112A.

[0286] In this case, the sensor element is mounted on the providing device 150.

[0287] If necessary, the increased residual moisture can be reduced by the heat generated by the burner device 146.

[0288] In particular, in the sense of the present invention, the function of the application device 110 can be manipulated by means of a determined residual moisture value.

[0289] In order to determine the particle size of the particles 112 or the powdered particle mixture 112A at the application device 110, the application device 110 has another detection device 154 whose sensor element (not shown here) can detect the particle size of the particles 112 or the powdered particle mixture 112A.

[0290] In particular, in the sense of the present invention, the function of the application device 110 can be manipulated by means of a determined particle size value.

[0291] In addition, in order to measure the exit velocity of the particles 112 at the exit nozzle 122, the application device 110 also has a measuring device 156 for measuring the exit velocity.

[0292] For this purpose, the measuring device 156 has one or more sensor elements (not shown) by means of which the exit velocity in the region 158 at or behind the exit nozzle 122 can be measured.

[0293] In particular, in the sense of the present invention, the function of the application device 110 can also be manipulated by means of a determined exit speed value.

[0294] In addition, in order to measure the outlet temperature of the particles 112 or the hot gas flow 120 at the outlet nozzle 122, the application device 110 has another measuring device 160 for measuring the outlet temperature.

[0295] Another measuring device 160 also has one or more sensor elements (not shown) by means of which the outlet temperature in the region 158 at or behind the outlet nozzle 122 can be measured.

[0296] In particular, in the sense of the present invention, the function of the application device 110 can also be manipulated by means of a determined outlet temperature value.

[0297] In addition, the application device 110 also has a suction device 162, which includes one or more suction elements (not explicitly shown here) having suction openings (not explicitly shown here) by means of which excess spray 126 can be suctioned from the surrounding environment 130 of the work roller 100 or particularly from the processing position 116.

[0298] The position of the suction device 162 or its suction element relative to the work roller 100 or in this respect relative to the axis of rotation 136A is adjustable.

[0299] For this purpose, the application device 110 or the suction device 162 has another detection device 164 by means of which the position can be detected.

[0300] If the suction device 162 or its suction element is arranged on a side 166 opposite to the outlet nozzle 122, the excess coating 126 can be advantageously directed away from the work roller 100.

[0301] Furthermore, in the sense of the present invention, the function of the application device 110 can be further manipulated by means of a determined position value.

[0302] If the application device 110 or the aforementioned mixing device 150B has another measuring device 168 for measuring the proportion of hard phase and / or matrix, the functions of the application device 110 can be conveniently accumulated.

[0303] For this purpose, another measuring device 168 has one or more sensor elements (not explicitly shown), which are preferably arranged on the providing device 150.

[0304] In addition, the application device 110 also has a cooling and / or cleaning device 170, by means of which the work roller 100 or the substrate 102 or the wear-resistant protective layer 104 can be cooled or cleaned as needed.

[0305] For this purpose, the cooling and / or cleaning device 170 has a nozzle element (not shown further) having a nozzle opening whose position relative to the work roller 100 is adjustable.

[0306] In this situation, the corresponding position can be determined by observing device 172.

[0307] In particular, in the sense of the present invention, the function of the application device 110 can be advantageously manipulated by means of a determined position value.

[0308] In order to better evaluate and control or regulate the various functions of the application device 110 in a coordinated manner, the application device 110 also has a higher level of control and / or regulation device 174.

[0309] On this point, it should be mentioned that, for clarity, not all electrical, data, or other connections and interfaces are explicitly shown.

[0310] In any case, using the application device 110 shown and explained herein, 65% or more of the particles 112 sprayed in the direction of the work roll 100 successfully adhere to the work roll 100, resulting in the application device 110 and the method performed therewith being able to operate extremely efficiently.

[0311] List of reference numerals

[0312]

[0313]

Claims

1. A method for manufacturing or repairing a work roll (100), comprising a substrate (102) and an abrasion-resistant protective layer (104), wherein particles (112) are thermally applied to the work roll (100), characterized in that, During the heat application of the particles (112), 50% or more of the particles (112) remain adhered to the substrate (102) and / or the applied wear-resistant protective layer (104), and remain on the substrate (102) and / or the wear-resistant protective layer (104), wherein Before applying the particles (112) to the substrate (102), the substrate (102) is preheated to a substrate temperature greater than or equal to 30°C, and wherein The particle mixture (112A) containing hard phase particles (112) and matrix particles (112) has less than or equal to 10%.

2. The method according to claim 1, characterized in that, During the heat application of the particles (112), 50% or less of the particles (112) bounce off the substrate (102) and / or the applied abrasion-resistant protective layer (104).

3. The method according to claim 1, characterized in that, The particles (112) have a particle size greater than or equal to 0.5 µm and / or less than or equal to 60 µm.

4. The method according to claim 1, characterized in that, The particles (112) are pre-screened to a particle size of less than or equal to 60 µm.

5. The method according to claim 4, characterized in that, The particles (112) are pre-screened on the application device (110).

6. The method according to claim 1, characterized in that, The particles (112) at or behind the outlet nozzle (122) of the application device (110) have an outlet velocity greater than or equal to 500 m / s, and / or have an outlet velocity less than or equal to 1500 m / s.

7. The method according to claim 6, characterized in that, The exit velocity is measured at a position or area (158) 100 mm or less from the exit nozzle (122).

8. The method according to claim 1, characterized in that, The particles (112) are discharged from the outlet nozzle (122) of the application device (110) by means of a hot air stream (120), wherein the particles (112) and / or the hot air stream (120) have an outlet temperature greater than or equal to 800°C, and / or the particles (112) and / or the hot air stream (120) have an outlet temperature less than or equal to 2200°C.

9. The method according to claim 8, characterized in that, The outlet temperature is adjusted according to the characteristics of the particles (112).

10. The method according to claim 8, characterized in that, The outlet temperature is measured at a location or area (158) 100 mm or less from the outlet nozzle (122).

11. The method according to claim 1, characterized in that, During the application of particles (112) to the work roller (100), an excess of spray (126) of particles (112) including at least not adhering to the substrate (102) is drawn from the surrounding environment (130) of the work roller (100) at a suction speed of greater than or equal to 10 m / s and / or at a suction speed of less than or equal to 30 m / s.

12. The method according to claim 11, characterized in that, In order to remove excess spray (126), at least one suction opening of the suction device (162) is arranged at a distance of greater than or equal to 0.1 m and / or at a distance of less than or equal to 1.5 m relative to the work roller (100).

13. The method according to claim 11, characterized in that, The distance between the work roller (100) and the suction opening is adjusted according to the suction speed.

14. The method according to claim 11, characterized in that, The suction speed and / or the distance between the substrate (102) and the suction opening are adjusted according to the exit speed of the particles (112) at or behind the outlet nozzle (122) of the application device (110).

15. The method according to claim 1, characterized in that, For a particle mixture (112A) containing hard phase particles (112) and matrix particles (112), a hard phase ratio of greater than or equal to 50% and / or less than or equal to 90% is set.

16. The method according to claim 1, characterized in that, Before applying the particles (112), the matrix (102) is preheated to a temperature less than or equal to 120°C.

17. The method according to claim 1, characterized in that, Before and / or during the application of the particles (112) to the work roll (100), the substrate (102) or the wear-resistant protective layer (104) already disposed thereon is processed by abrasive and / or subtractive processing.

18. The method according to claim 17, characterized in that, Before and / or during the application of the particles (112) to the work roll (100), the abrasion-resistant protective layer (104) is at least partially and / or partially removed.

19. The method according to claim 17, characterized in that, Before applying the particles (112) to the processed old wear-resistant protective layer (104), the old wear-resistant protective layer (104) already arranged on the substrate (102) is processed by a subtractive process.

20. The method according to claim 1, characterized in that, The wear-resistant protective layer (104) is post-treated.

21. The method according to claim 1, characterized in that, The substrate (102) is provided in a semi-automatic or automatic manner.

22. The method according to claim 21, characterized in that, The substrate (102) is automatically measured and the actual value is determined accordingly.

23. The method according to claim 21, characterized in that, At least one coating parameter is automatically determined based on the actual value.

24. The method according to claim 21, characterized in that, The substrate (102) is automatically preheated according to the determined actual value.

25. The method according to claim 21, characterized in that, The wear-resistant protective layer (104) applied to the substrate (102) is automatically re-inspected.

26. The method according to claim 21, characterized in that, Automatically identify and record the manufactured work rolls (100).

27. The method according to claim 21, characterized in that, Automatically generate recovery samples.

28. The method according to claim 1, characterized in that, The new wear-resistant protective layer (104) applied to the substrate (102) is processed by a subtractive processing method.

29. An application device (110) for applying particles (112) onto a substrate (102) of a work roller (100), i.e., a heat application device (110), comprising a burner device (146), for carrying out the method according to any one of claims 1 to 28, characterized in that, The application device (110) has a detection device (152) for detecting residual moisture in a particulate mixture (112A) comprising hard phase particles (112) and matrix particles (112), wherein the detection device (152) has one or more sensor elements, and The application device (110) is configured such that during the process of applying heat to the work roll (100) the particles (112), 50% or more of the particles (112) remain on the substrate (102) and / or have been applied to the wear-resistant layer (104) on the substrate (102) and adhere to the substrate (102) and / or the wear-resistant layer (104).

30. The application device (110) according to claim 29, characterized in that, The application device (110) is configured such that 60% or more of the particles (112) remain adhered to the substrate (102) and / or the applied abrasion-resistant protective layer (104) and remain on the substrate (102) and / or the abrasion-resistant protective layer (104).

31. The application device (110) according to claim 29 or 30, characterized in that, The application device (110) is configured such that 40% or less of the particles (112) bounce off the substrate (102) and / or the applied abrasion-resistant protective layer (104) during the application of heat to the work roll (100).

32. The application device (110) according to claim 29, characterized in that, The application device (110) has a screening device (150C) for screening the particles (112) according to their particle size, wherein the screening device (150C) has one or more screening elements.

33. The application device (110) according to claim 29, characterized in that, The application device (110) includes another detection device (154) for detecting particle size, wherein the other detection device (154) has one or more sensor elements.

34. The application device (110) according to claim 29, characterized in that, The application device (110) includes a measuring device (156) for measuring the exit velocity of the particles (112) at the exit nozzle (122), wherein the measuring device (156) has one or more sensor elements by means of which it is able to measure the exit velocity at or behind the exit nozzle (122).

35. The application device (110) according to claim 29, characterized in that, The application device (110) has another measuring device (160) for measuring the outlet temperature of the particles (112) at the outlet nozzle (122), wherein the other measuring device (160) has one or more sensor elements by means of which it is able to measure the outlet temperature at or behind the outlet nozzle (122).

36. The application device (110) according to claim 29, characterized in that, The application device (110) has a suction device (162) for drawing out excess spray (126) including particles (112) that do not adhere to the substrate (102) from the surrounding environment (130) of the substrate (102), wherein the suction device (162) has one or more suction elements having adjustable suction openings.

37. The application device (110) according to claim 36, characterized in that, The suction device (162) includes another detection device (164) for detecting the position of one or more suction elements relative to the work roller (100).

38. The application device (110) according to claim 36, characterized in that, The one or more suction elements are arranged on one side (166) of the outlet nozzle (122) facing away from the application device (110) relative to the application roller (100).

39. The application device (110) according to claim 29, characterized in that, The application device (110) includes a mixing device (150B) for mixing the particles (112) with hard phase particles (112) and matrix particles (112), wherein the mixing device (150B) has another measuring device (168) for measuring the proportion of hard phase and / or matrix, wherein the other measuring device (168) has one or more sensor elements.

40. The application device (110) according to claim 29, characterized in that, The application device (110) has an abrasive or subtractive processing device (144) by means of which it is able to process the substrate (102) and / or the wear-resistant protective layer (104).

41. The application device (110) according to claim 29, characterized in that, The application device (110) has a supply device (138) for supplying the substrate (102) to the processing position (116), a rotation device (136) for rotating the substrate (102) at the processing position (116), and / or a removal device (140) for removing the work roller (100) from the processing position (116), wherein the supply device (138), the rotation device (136), and the removal device (140) operate in a semi-automatic or fully automatic manner.

42. The application device (110) according to claim 29, characterized in that, The application device (110) has a cooling and / or cleaning device (170), wherein the cooling and / or cleaning device (170) has one or more nozzle elements having adjustable nozzle openings.

43. The application device (110) according to claim 29, characterized in that, The application device (110) includes a feeding device (150) for feeding particles (112), wherein the feeding device (150) is configured to feed the particles (112) with a feeding tolerance of + / - 2 g / min relative to the feeding amount.

44. The application device (110) according to claim 29, characterized in that... A control and / or regulating device, wherein the control and / or regulating device is configured to automatically control or regulate one or more devices (136, 138, 140, 144, 146, 150, 150A, 150B, 150C, 152, 154, 156, 160, 162, 164, 168, 170, 172, 174) of the applying device (110).

45. The application device (110) according to claim 29, characterized in that, The application device has a layer thickness control device, which is configured to measure the layer thickness of the wear-resistant protective layer (104).

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