Method for manufacturing or repairing work rolls, rolling stand, metal strips, and coating apparatus for applying particles.

Abstract

The present invention relates to a method for manufacturing or repairing a work roll (100) comprising a base (102) and an abrasion protection layer (104), wherein the method involves thermally coating the work roll (100) with particles (112), characterized in that, while the particles are thermally coated, 50% or more, preferably 60% or more, or 75% or more, and particularly preferably 80% or more of the particles adhere to the base and / or the already coated abrasion protection layer and remain on the base and / or the abrasion protection layer.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing or repairing a working roll having a substrate and a wear protection layer, in which a coating material containing particles is thermally applied to the substrate.

[0002] The present invention further relates to a working roll having a substrate and a wear protection layer for rolling a metal material.

[0003] The present invention also relates to a rolling stand for processing a metal material such as a metal strip.

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

[0005] The present invention further relates to an application device for applying particles to a substrate of a working roll, which includes a burner device and an open-loop control and / or closed-loop control device for open-loop control and / or closed-loop control of the application device.

Background Art

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

Summary of the Invention

Problems to be Solved by the Invention

[0007] The problem underlying the present invention is to provide an improved or alternative form to the prior art.

Means for Solving the Problems

[0008] The problem of the present invention is solved by a method for manufacturing or repairing a work roll comprising a substrate and an abrasion protection layer, wherein, according to a first aspect of the present invention, a coating material containing particles is thermally applied to the work roll, characterized in that, during the thermal application of the particles, 50% or more, preferably 60% or more, or 75% or more, and particularly preferably 80% or more of the particles adhere to the substrate and / or the already applied abrasion protection layer and remain on the substrate and / or the abrasion protection layer.

[0009] By using this method, we succeed in ensuring that at least about 50% of the particles adhere to the substrate or its wear protection layer and are not lost, thereby enabling the manufacture or repair of work rolls or their wear protection layers to be carried out very efficiently, and in particular, very resource-saving.

[0010] Conventional manufacturing methods for standard work rolls have resulted in significant particle loss of approximately 50%, and often even more, because the particles involved often do not adhere sufficiently when they collide with the surface of the work roll and are lost accordingly, and / or, during the coating process, in the path of the particles from the burner device outlet nozzle toward the surface of the work roll, they interact particularly with the airflow surrounding the surface of the work roll, especially with local vortices, and do not reach the surface of the work roll and do not hit the part.

[0011] Reusing a non-adhering particle mixture requires separating the particle mixture back into a pure substance and / or re-granulating the pure substance. However, this particle mixture is practically unusable due to its complex structure, especially when combined with processing by thermal coating methods.

[0012] The present invention makes it possible to significantly reduce or completely avoid the drawbacks of the prior art.

[0013] In particular, coating efficiency can also be determined by the selection of the coating equipment or its process burner.

[0014] This manufacturing or repair method is a thermal coating method, more precisely, a thermal spraying method for thermally spraying particles onto the substrate of a work roll used for rolling a metal material such as a thin metal strip and / or an existing wear protection layer thereon.

[0015] First, it should be noted that within the scope of this patent application, indefinite articles and indefinite numbers such as "one," "two," etc., should generally be understood as "at least one," "at least two," etc., unless it is clear from the context of a particular section or specific wording that only "exactly one," "exactly two," etc., is intended.

[0016] It should also be noted that, within the scope of this patent application, the expression “especially” should always be understood as introducing an optional, preferred feature. This expression should not be interpreted as “moreover” or “that is.”

[0017] The particles can be designed in various ways within the context of this invention, but are preferably designed as ceramic particles and / or metal particles. In some cases, other particles can also be provided as functional materials, auxiliary materials, fillers, etc.

[0018] In this case, the particles or particle mixture are in powder form and can provide a starting material for producing an abrasion protection layer.

[0019] To that extent, particles or particle mixtures can be recycled as powder, and accordingly, they can be provided or processed in powder form in a coating apparatus.

[0020] According to a first variant of the particles provided in powder form, the particles can also be provided as a suspension for use as a starting material for creating an abrasion protection layer.

[0021] In that case, the suspension contains particles dispersed in a liquid phase. The liquid phase can include water and / or ethanol and / or isopropanol and / or the like. In particular, a liquid phase with a low enthalpy of evaporation can be used, especially a liquid phase with an enthalpy of evaporation of 2.5 kJ / g or less.

[0022] Furthermore, the suspension can include a dispersant, especially citric acid, HNO3, diammonium citrate, C5H8O2, etc.

[0023] The suspension is partially evaporated under the action of the thermal energy of the high-temperature gas stream generated by the burner device. Usually, the suspension is partially evaporated before the suspension comes into contact with the substrate and / or the wear protection layer, i.e., especially before the particles thus obtained are thermally applied. The particles do not evaporate, while the liquid phase and / or the dispersant evaporate. Insofar as that, the particles or particle mixture can also be provided as a suspension to the burner device within the scope of this specification.

[0024] It has been shown that a wear protection layer with a low roughness value and / or a low porosity and / or especially a high hardness can be produced using the suspension.

[0025] According to a second variant form of the particles provided in powder form, the particles can also be provided in wire form and / or rod form as starting materials for the production of the wear protection layer. The corresponding wire (core wire) or rod (mandrel) for providing the particles can have a coating and the particles enclosed in the coating.

[0026] When a wire or rod is used as the starting material for the particles to thermally apply the wear protection layer, the starting material can be melted by the high-temperature gas stream provided by the burner device and / or by generating a plasma between the anode and the cathode to melt it. Usually, this is done before the particles thus obtained come into contact with the substrate and / or the wear protection layer, i.e., especially before the particles thus obtained are thermally applied. Insofar as that, the particles or particle mixture can also be provided as a wire and / or rod to the burner device within the scope of this specification.

[0027] In this case, suitable particles can be formed as a hard phase or hard phase particles and / or as a matrix or matrix particles.

[0028] As such, in the context of the present invention, the term "hard phase" represents relatively hard particles embedded in a softer matrix in the wear protection layer, and the softer matrix is produced using matrix particles during thermal spraying.

[0029] Hard phases suitable for the wear protection layer can here in particular advantageously be hard phases of oxides, carbides or borides having a high hardness. For example, a compound of silicon and carbon can be used to form silicon carbide (SiC).

[0030] Correspondingly, the term "matrix" represents the structure that supports the hard phase in the wear protection layer. As such, the hard phase is embedded in and arranged within the matrix.

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

[0032] Particularly preferably, the hard phase particles have a tungsten carbide (WC) proportion of 50 wt% or more, preferably 60 wt% or more, particularly preferably 70 wt% or more.

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

[0034] By virtue of the weight proportion of tungsten carbide, particularly as a component of the hard phase of the wear protection layer, the hardness of the wear protection layer can advantageously be increased, and by increasing the proportion of tungsten monocarbide (WC) in the wear protection layer, the hardness of the wear protection layer is further increased.

[0035] The abrasion protection layer may, advantageously, have a tungsten carbide (WC) content of 2% by weight or more, preferably 20% by weight or more, and particularly preferably 25% by weight or more or 30% by weight or more. More advantageously, the abrasion protection layer may have a tungsten carbide (WC) content of 40% by weight or more, preferably 45% by weight or more, and particularly preferably 65% ​​by weight or more or 70% by weight or more. Particularly advantageously, the abrasion protection layer may have a tungsten carbide (WC) content of 75% by weight or more, preferably 80% by weight or more, and particularly preferably 85% by weight or more or 87% by weight or more.

[0036] Preferably, the wear protection layer is made of tungsten carbide (WC), aluminum oxide (Al2O3), zirconium oxide (ZrO2), chromium carbide (Cr3C2, Cr7C3 and / or Cr 23 C6), containing at least one, two, three, four, five, six, or seven or more elements from 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), and in particular tungsten carbide (WC), aluminum oxide (Al2O3), zirconium oxide (ZrO2), chromium carbide (Cr3C2, Cr7C3 and / or Cr 23 It contains at least one, two, three, or four or more elements, including 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, and the composition of the matrix particles is substantially equivalent to the composition of the matrix of the wear protection layer made using the matrix particles.

[0038] By using iron as a component of the matrix of the wear protection layer made of matrix particles, it is possible to achieve a relatively inexpensive wear protection layer matrix. This can be particularly advantageous when the work roll wears out faster than the wear protection layer corrodes.

[0039] By using nickel as a matrix particle, and therefore as a component of the matrix of the wear protection layer, the chemical resistance of the matrix of the wear protection layer can be improved. Depending on the alloy of the wear protection layer, using a nickel-containing matrix can achieve overall chemical resistance, and especially corrosion resistance, of the wear protection layer.

[0040] Cobalt as a component of matrix particles, and consequently as a component of the matrix in the wear protection layer, can potentially improve the temperature resistance of the wear protection layer. Cobalt can also, advantageously, increase the hardness of the matrix and therefore the entire wear protection layer.

[0041] By using molybdenum as a component of matrix particles, and consequently as a component of the matrix of the wear protection layer, the chemical resistance and / or temperature resistance of the wear protection layer, particularly the matrix, can be improved.

[0042] If the matrix contains tungsten, it may be advantageous for the temperature resistance of the matrix, and consequently for the temperature resistance of the entire wear protection layer, making tungsten a favorable component of matrix particles.

[0043] It has been shown that the adhesive properties of the matrix, and consequently the adhesive properties of the abrasion protection layer itself, can be improved by using boron as a matrix component, making boron an advantageous component of matrix particles.

[0044] Furthermore, the matrix particles, and by extension the matrix of the wear protection layer, may contain manganese, copper, chromium, and / or silicon, thereby further optimizing the matrix of the wear protection layer with respect to its ductility, hardness, chemical resistance, machinability, friction properties, temperature resistance, adhesion, and / or similar properties.

[0045] To that extent, it is advantageous that during the thermal application of the particles, 50% or less, preferably 40% or less, or 25% or less, and particularly preferably 20% or less, of the particles that bounce back from the substrate and / or the already applied abrasion protection layer.

[0046] This ensures a significant improvement in efficiency with respect to this method.

[0047] The purposeful adhesion of particles on a work roll in the sense of the present invention can already be achieved if the residual moisture content of the particle mixture, which includes hard phase particles and matrix particles, is 10% or less, preferably 5% or less, and particularly preferably 2% or less.

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

[0049] In this case, the residual moisture content is measured before adding particles or a mixture of particles to the high-temperature gas stream of the coating apparatus.

[0050] If the residual moisture content exceeds the above value, it is advantageous to reduce the residual moisture content to 10% or less, preferably 5% or less, and particularly preferably 2% or less, before adding the particles to the high-temperature gas flow.

[0051] To that extent, this method, in particular, is advantageous when other method parameters are manipulated according to the residual moisture content of the particle mixture.

[0052] To give just one example, the outlet temperature of the high-temperature gas stream that comes out of the outlet nozzle of the coating device along with the particles can be controlled according to the residual moisture content.

[0053] Furthermore, with regard to the distribution of moisture in the particle mixture in particular, the residual moisture content can be reduced for a more uniform particle mixture, thereby achieving improved particle adhesion on the substrate and / or abrasion protection layer.

[0054] To that extent, the residual moisture content can guarantee a favorable improvement in efficiency for this method.

[0055] The favorable adhesion of particles to the work roll in the sense of the present invention can already be achieved, or can be cumulatively improved, if the particle diameter is 0.5 μm or more, preferably 1 μm or more, and / or 60 μm or less, preferably 30 μm or less, and particularly preferably 15 μm or less.

[0056] In the context of this invention, the term "particle diameter" refers to the average powder diameter of a powder consisting of particles that provide the starting material for the abrasion protection layer.

[0057] For example, in this case, the smaller the particle size or average powder diameter, the lower the outlet velocity (particle velocity) of the high-temperature gas flow at the outlet nozzle of the coating device can usually be selected. On the other hand, by reducing the particle size, the level of the outlet temperature at the outlet nozzle of the coating device can be controlled.

[0058] It has been confirmed that reducing particle size improves the average adhesion or bonding strength of particles on the coating roll (without changing heat transfer), and this can also affect coating efficiency.

[0059] To that extent, simply selecting the particle size can already influence the degree of particle adhesion on the work roll.

[0060] To that extent, the powder size can guarantee a favorable improvement in efficiency with respect to this method.

[0061] Other favorable interactions that can be reliably obtained with respect to particle size can be read from the table below.

[0062] [Table 1]

[0063] Table 1: Particle size (μm) of powdered particle mixture: roughness of the abrasion protection layer, roughness of the product (thin strip) processed by the work roll, residual stress of the abrasion protection layer and / or substrate, porosity, hardness, peak count, uniformity, especially uniformity of the distribution of coating elements within the abrasion protection layer and uniformity of the thickness of the abrasion protection layer, (coating) elemental distribution, adhesive tensile strength, peel resistance, and dispersion width (each evaluated on a scale of 0 to 10, with individual scales ranging from the minimum possible (0) to the maximum possible (10) (scale name: kg), and neutral (0) to the best possible (10) (scale name: nb).)

[0064] In order to ensure that such advantageous particle size is reliably guaranteed in the coating apparatus, it is advantageous to pre-screen the particles to a particle size of 60 μm or less, preferably 30 μm or less, and particularly preferably 15 μm or less.

[0065] The proposed particle size can, for the benefit of the system, influence the dispersion width of the powder particle mixture, and in particular, can be reduced.

[0066] Strictly speaking, as the particle size increases, the dispersion width over which the particles collide with the work roll can be narrowed.

[0067] It has been shown that reducing the particle size allows for a higher (compressive) residual stress level in the abrasion protection layer, which can have a favorable effect, at least indirectly, on the adhesive tensile strength and / or peel resistance of the abrasion protection layer. Furthermore, or depending on the above embodiment, smaller particle sizes can contribute to a lower porosity in the abrasion protection layer, thereby further improving the peel resistance of the abrasion protection layer.

[0068] In the sense of the present invention, when particles or particle mixtures are sieved beforehand, undesirable impurities can also be sufficiently removed in advance.

[0069] Furthermore, the proposed pre-sieving method allows for greater uniformity of the powdered particle mixture, thereby enabling a reasonably good uniformity of the wear protection layer.

[0070] Overall, pre-screening ensures a more stable coating process.

[0071] For example, it is advantageous that the particles are pre-screened in the coating apparatus, particularly before being added to the high-temperature gas flow of the coating apparatus, in order to provide suitable starting materials for creating different wear protection layers for various work rolls used in coating apparatuses.

[0072] For this purpose, by pre-screening the starting materials or particles, the parameters of the particle mixture can be more accurately adjusted using this method.

[0073] In the sense of the present invention, the adhesion force of particles on the work roll can also be positively affected if the outlet velocity of particles at or behind the outlet nozzle of the coating device is 500 m / sec or more, preferably 800 m / sec or more, particularly preferably 900 m / sec or more, and / or the outlet velocity is 1500 m / sec or less, preferably 1200 m / sec or less, particularly preferably 1000 m / sec or less.

[0074] If a lower exit velocity is selected, when particles collide with the work roll, they cannot bond as tightly to each other with the substrate and / or the wear protection layer already present on the substrate, thereby increasing the porosity and / or permeability of the wear protection layer in particular.

[0075] On the other hand, if a higher exit speed is selected, the resulting level of compressive residual stress in the abrasion protection layer can be increased, thereby advantageously increasing the adhesive tensile strength of the abrasion protection layer. However, there is a higher risk that particles may bounce off the surroundings and be lost upon impact with the work roll, which could reduce coating efficiency.

[0076] In other words, this means that by manipulating the exit velocity, it is possible to influence the kinetic energy inherent to the particles upon collision with the coating roll, which in turn affects the adhesion of the particles to the coating roll.

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

[0078] For example, the exit velocity affects the particle temperature because a higher exit velocity shortens the contact time with the burner flame, which in turn reduces the particle temperature at the point of impact with the work roll.

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

[0080] For example, distorted measurements may negatively affect the adhesion conditions of particles to the work roll, but in this case, the risk of significant impact on the measurement due to ambient influences can be reduced.

[0081] For example, if the outlet velocity of the high-temperature gas flow is adjusted according to the characteristics of the particles, the adhesion force can also be manipulated in a purposeful manner.

[0082] To that extent, particle adhesion on the work roll in the sense of the present invention can already be achieved, or cumulatively improved, simply by favorably selecting the exit velocity, as proposed herein.

[0083] Cumulatively or alternatively, the adhesion force of particles on the work roll can also be adjusted if the particles are carried out from the outlet nozzle of the coating device by a high-temperature gas stream, the outlet temperature of the particles and / or the high-temperature gas stream being 800°C or higher, preferably 1000°C or higher, particularly preferably 1200°C or higher, and / or the outlet temperature of the particles and / or the high-temperature gas stream being 2200°C or lower, preferably 2000°C or lower, particularly preferably 1800°C or lower.

[0084] For example, particles are heated by a high-temperature gas stream, in which case they are melted or liquefied to that extent, and the degree of such melting and liquefaction depends particularly on the particle size.

[0085] Overall, this also allows for adjustment of the adhesion force of the particles.

[0086] This can also affect the layer quality of the wear protection layer.

[0087] The outlet temperature can be adjusted, for example, according to the residual moisture content and / or particle size.

[0088] To that extent, it is advantageous when the outlet temperature is adjusted according to the characteristics of the particles.

[0089] If the residual moisture content is higher, it may be advantageous to select a higher outlet temperature.

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

[0091] When the outlet temperature is measured at a location or area located at a distance of 100 mm or less, preferably 50 mm or less, and particularly preferably 10 mm or less from the outlet nozzle, a particularly convincing value regarding the outlet temperature can be measured.

[0092] The experimental results show that the outlet temperature of particles and / or high-temperature gas streams can be advantageously measured by placing the nozzle at a distance of 5 mm to 15 mm behind the outlet nozzle.

[0093] Another highly advantageous variation of the method may be provided in which, while particles are being applied to the work roll, an overspray surrounding the work roll, including at least particles that do not adhere to the substrate, process gases, combustion products, etc., is sucked from around the work roll at a suction speed of 10 m / s or more, preferably 15 m / s or more, particularly preferably 18 m / s or more, and / or 30 m / s or less, preferably 25 m / s or less, particularly preferably 20 m / s or less.

[0094] By using this method of suction, it is possible to avoid the undesirable loss of particles.

[0095] On the one hand, the degree of overspray critically surrounding the work roll can be advantageously reduced if the associated interfering elements are removed from very close to the work roll, especially after contact with the work roll.

[0096] Such interfering elements may include, for example, excessive particles, process gases, and combustion products, and if they cannot be properly removed, they may cause quality problems in the wear protection layer due to the corresponding contaminants or defects.

[0097] On the other hand, by selecting a suction speed within the proposed range of values, it is possible to avoid, in particular, particles that have not yet come into contact with the work roll deviating unfavorably from their intended trajectory, thereby missing the target on the work roll or only making unfavorable contact with the work roll.

[0098] Therefore, improvement in particle adhesion on the work roll in the sense of the present invention can be achieved by this alone or cumulatively. Furthermore, this can also improve the layer quality of the wear protection layer.

[0099] Furthermore, in order to remove overspray, it is advantageous that at least one suction opening of the suction device is positioned at a distance of 0.1 m or more, preferably 0.2 m or more, from the work roll, and / or at a distance of 1.5 m or less, preferably 1 m or less, preferably 0.5 m or less.

[0100] The distance proposed here ensures that overspray is reliably removed from the work roll or its surroundings.

[0101] In this case, at least one suction opening is preferably located on the side of the work roll opposite the outlet nozzle, so that particles flowing alongside the work roll or bouncing off the work roll can be directly sucked up from around the work roll.

[0102] It is also possible to provide another or additional location for arranging at least one suction opening or multiple suction openings, either cumulatively or alternatively.

[0103] It is appropriate for the distance between the work roll and the suction opening to be adjusted according to the suction speed.

[0104] This makes it possible to avoid, or at least significantly reduce, the risk of negative effects from air motion or air vortices in the immediate vicinity of the work roll.

[0105] The suction speed or suction distance may also cause an additional cooling effect on the work roll, for example, by the airflow generated by the suction, which can flow along the surface of the work roll, particularly its substrate or wear protection layer.

[0106] In particular, to allow for further control of the temperature during thermal application of particles, the suction opening can be positioned at a distance from the work roll depending on the existing suction force.

[0107] For example, adjusting the suction speed and / or the distance between the substrate and the suction opening according to the exit velocity of particles at or behind the outlet nozzle of the coating device can positively affect the adhesion force of the particles.

[0108] This can also affect the coating temperature.

[0109] The suction method described herein alone can achieve, or cumulatively improve, the favorable adhesion of particles to the work roll in the sense of the present invention, as proposed herein.

[0110] This also allows the method to be implemented more efficiently.

[0111] Furthermore, with respect to particle mixtures containing hard phase particles and matrix particles, it is advantageous when the hard phase component is adjusted to 50% or more, preferably 55% or more, and particularly preferably 60% or more, and / or when the hard phase component is adjusted to 90% or less, preferably 85% or less, and particularly preferably 80% or less.

[0112] [Table 2]

[0113] Table 2: Ratio of hard phase component in particle mixture, i.e., ratio of hard phase to the entire layer system consisting of hard phase and matrix: hardness and roughness R of the abrasion protection layer, respectively. a Density, uniformity of elemental distribution, uniformity of layer thickness distribution, peak count, adhesive tensile strength, residual stress, and porosity (each evaluated on a scale of 0 to 10, with individual scales ranging from the minimum possible (0) to the maximum possible (10) (scale name: kg) and from neutral (0) to the best possible (10) (scale name: nb)).

[0114] In particular, such hard phase components can favorably influence the hardness of the wear protection layer.

[0115] To that extent, it is advantageous when the hard phase component in the particle mixture as a whole has the values ​​described above.

[0116] Another favorable interaction related to this can be seen in the table below.

[0117] Another advantageous adhesion of particles on a work roll in the sense of the present invention can be achieved, or cumulatively improved, by preheating the substrate to a substrate temperature of 30°C or higher, preferably 50°C or higher, particularly preferably 60°C or higher, and / or to a substrate temperature of 120°C or lower, preferably 150°C or lower, particularly preferably 200°C or lower, before applying the particles.

[0118] In particular, preheating the substrate in this manner can achieve a favorable improvement in layer adhesion for the wear protection layer on the substrate of the work roll, and to that extent, an improvement in layer quality can also be achieved.

[0119] In that case, it was confirmed that improving the layer quality could also be achieved by heating the substrate to a higher temperature.

[0120] In particular, a heated substrate can favorably influence the stress state in the wear protection layer.

[0121] Furthermore, by preheating the substrate, it may be possible to reduce and / or minimize the residual moisture content of the substrate, particularly adsorbed water, and / or gases accumulated in the substrate.

[0122] The wear protection layer applied by the method described herein is ready for use on the work roll, but the wear protection layer may be further treated after the initial application as needed, for example by grinding and / or subtractive manufacturing.

[0123] In the sense of the present invention, if the substrate or a wear protection layer already applied thereto is ground and / or subtracted before and / or during the application of particles to the work roll, the adhesion of the particles can generally be improved in at least some areas.

[0124] In particular, this allows for the proper refurbishment or repair of work rolls that have already been used.

[0125] In particular, with respect to repair, it is advantageous if at least a portion and / or part of the wear protection layer is removed before and / or during the application of particles to the work roll.

[0126] This significantly improves particle adhesion to the wear protection layer already present on the substrate of used work rolls.

[0127] This is especially true when machining an existing wear protection layer already placed on a substrate using a subtractive machining method, before applying particles to the machined old wear protection layer.

[0128] Further treatment to add a wear-protective layer can be achieved when the wear-protective layer is post-treated, particularly by the EDT (electrical discharge texturing) method.

[0129] Customer-specific requirements for the wear protection layer of the work roll, particularly the texturing of the work roll wear protection layer, can be easily established in relation to this post-processing method.

[0130] This coating method can be further advantageously developed when the substrate is supplied semi-automatically or automatically.

[0131] Automation in this area allows for more precise control and coordinated execution of the process, which in turn can have a favorable impact, particularly on the adhesion force of particles on the work rolls.

[0132] In variations of the semi-automatic method, further manual intervention by an operator may be required during or after the process, whereas in variations of the fully automated method, such manual intervention is not necessarily required.

[0133] In the sense of the present invention, the wear protection layer attached to the coating roll can be attached to the coating roll more accurately by this coating method when the substrate is automatically measured, thereby detecting an actual value, and in particular when the detected actual value is compared with a target value.

[0134] The proposed measurements can be performed at various points in time, in particular, before, during, and / or after providing the substrate to the coating apparatus, in connection with the proposed method.

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

[0136] In particular, the coating parameters already described above can be detected automatically, at least partially, in the sense of the present invention.

[0137] This makes it possible to achieve, in particular, favorable adhesion of particles to the work roll in the sense of the present invention.

[0138] In relation to the proposed method, detection of coating parameters can be performed at various points in time, particularly before, during, and / or after the application of particles to the substrate in the coating apparatus.

[0139] As already mentioned above, if the substrate is automatically preheated to the substrate temperature described above in accordance with the detected actual values, this can favorably influence particle adhesion on the work roll in the sense of the present invention.

[0140] When the wear protection layer applied to the substrate is automatically inspected, especially optically, the degree of automation can be further developed to its advantage.

[0141] This allows for easier, faster, and more reliable control over the quality of the manufactured work rolls.

[0142] The detected data regarding the work rolls being manufactured can be reliably assigned to the work rolls if the work rolls being manufactured are automatically labeled and registered, for example, by barcodes, RFID chips, or similar means.

[0143] If preliminary samples are generated automatically, quality assurance using this method can be further improved.

[0144] Optionally, a new wear protection layer applied to the substrate is processed using a subtractive machining method, particularly by post-treatment, and especially by grinding and / or selective laser melting.

[0145] Preferably, the peaks of the applied wear protection layer are destroyed by grinding, particularly by abrasion, and / or the peaks of the wear protection layer are rounded by selective laser melting.

[0146] This results in less material being removed from the wear protection layer when using the work rolls, especially when rolling metal materials. This extends the lifespan of the wear protection layer and advantageously reduces contamination of the rolled strip by the removed wear protection layer.

[0147] Furthermore, this reduces the transfer of the coating from the metal material to the work rolls during rolling of coated products, especially galvanized metal materials, thereby improving the service life of the wear protection layer and the quality of the rolled thin strip.

[0148] The problem of the present invention is solved, according to a second aspect, by a work roll comprising a substrate and an abrasion protection layer for rolling a metal material, particularly for rolling a thin metal strip, which is manufactured by a method according to one of the features described herein.

[0149] The rolls manufactured in the sense of the present invention can be used to mechanically process metal materials, particularly their surfaces, to a higher quality and value.

[0150] Furthermore, work rolls manufactured or repaired by the method of the present invention typically have a longer service life.

[0151] The problem of the present invention can also be solved by a rolling stand for processing metal materials such as metal strips, according to a third aspect, which is equipped with a work roll having one of the features described herein.

[0152] By setting up a rolling stand equipped with working rolls here, setup work can be further reduced, or the setup interval can be further extended.

[0153] This is particularly due to the fact that the work rolls have a longer service life and, to that extent, can be used for a longer period in the rolling stand.

[0154] The problems of the present invention can also be solved by using a thin metal strip, which is rolled using the work rolls described herein, and in particular by cold rolling.

[0155] Advantageously, specific characteristics of the wear protection layer can be recognized based on the surface pattern achieved in the metal strip.

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

[0157] By processing metal strips with this work roll, it is possible to manufacture metal strips of extremely high quality.

[0158] The above problems are solved by a coating device for coating particles onto a work roll substrate, particularly a thermal coating device, which comprises a burner device, in particular an HVOF burner (high-speed oxygen fuel burner) and / or an HVAF burner (high-speed air fuel burner) and / or a similar device, wherein the coating device is configured such that, while thermally coating the particles onto the work roll, 50% or more of the particles adhere to the substrate and / or an already coated abrasion protection layer and remain on the substrate and / or abrasion protection layer.

[0159] This coating device successfully ensures that at least approximately 50% of the particles adhere to the substrate or its wear-protective layer and are not lost.

[0160] To that extent, the coating apparatus functions particularly efficiently with respect to both the creation and repair of the work roll or its wear-protective layer.

[0161] It is particularly advantageous if the coating apparatus is configured such that 60% or more, preferably 75% or more, and especially preferably 80% or more of the particles adhere to and remain on the substrate and / or the already coated abrasion protection layer.

[0162] This allows the coating device to operate particularly efficiently.

[0163] In particular, such a coating apparatus can significantly improve the method of applying particles to a substrate for creating or repairing a wear-protective layer on a work roll.

[0164] Preferably, the coating apparatus is configured such that, while thermally coating the work roll with particles, 40% or less, preferably 25% or less, and especially preferably 20% or less of particles bounce off the substrate and / or already applied abrasion protection layer, so that the coating apparatus can operate very efficiently. In particular, this method can achieve a particularly resource-efficient method.

[0165] The efficiencies described herein can be advantageously achieved when the coating apparatus is equipped with a detection device for detecting the residual moisture content of a particle mixture containing hard phase particles and matrix particles, and the detection device has one or more sensor elements.

[0166] Advantageously, in a coating apparatus, if at least one of its sensor elements is located in a dispensing device for providing a particle mixture, the detection device of the coating apparatus can inspect the particles with respect to their residual moisture content.

[0167] The providing device related to this can be advantageously realized when the providing device includes a powder conveyor, a powder mixer, or something similar.

[0168] Cumulatively or alternatively, it is advantageous for the coating apparatus to be equipped with a sieving device for screening particles with respect to their particle size, and for the sieving device to have one or more sieving elements.

[0169] For example, in a coating apparatus, various particles can be simultaneously or continuously screened by multiple sieving elements, particularly according to different particle sizes and pre-screened according to the particle material.

[0170] To that extent, the particles in the coating apparatus can be pre-screened using a sieving device as needed before being provided.

[0171] Needless to say, various suitable sieving devices can be designed and made available for use in coating equipment.

[0172] If the sieving device is located in a dispensing device for providing particles, such as a powder conveyor or powder mixer, the sieving device can be structurally simple and compactly implemented in the coating device.

[0173] The efficiency of this coating apparatus can also be advantageously achieved or improved by the sieving apparatus described herein.

[0174] The coating apparatus can be designed to be even more advantageous if it includes a separate detection device for detecting particle size, and the detection device has one or more sensor elements.

[0175] The efficiency of this coating apparatus can be advantageously achieved, or even further enhanced, by using another detection device in the coating apparatus.

[0176] Sensor elements or multiple sensor elements can be implemented and arranged in various ways within the coating apparatus.

[0177] A favorable implementation variant is intended in which at least one sensor element of another detection device is located in a supplying device for supplying particles, the supplying device may comprise a powder conveyor, a powder mixer or the like.

[0178] Furthermore, the efficiency of the coating apparatus in the sense of the present invention can also be achieved, or further enhanced, when the coating apparatus is equipped with a measuring device for measuring the outlet velocity of particles at the outlet nozzle, and the measuring device has one or more sensor elements.

[0179] Purposefully, 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 placed at or behind the exit nozzle.

[0181] Furthermore, it is appropriate if the coating apparatus includes a separate measuring device for measuring the outlet temperature of particles at the outlet nozzle, and the separate measuring device has one or more sensor elements.

[0182] This also makes it possible to achieve or further improve the efficiency of the coating apparatus in the sense of the present invention.

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

[0184] For this purpose, at least one sensor element can be placed at or behind the exit nozzle.

[0185] The efficiency achieved in the sense of the present invention can also be achieved if the coating apparatus includes a suction device for sucking up overspray, including at least particles, process gases, combustion products, etc., that are not adhering to the substrate, from around the substrate, and has one or more such suction devices.

[0186] Such suction devices can be designed and arranged in various ways within a coating apparatus.

[0187] When the suction element can be flexibly positioned relative to the work roll, it is advantageous that the suction device can be adjusted to suit the particles to be processed.

[0188] To that extent, it is purposeful if the suction element or its suction opening is adjustable with respect to each state position (Lageposition) relative to the work roll.

[0189] To that extent, the suction device is particularly suitable if it has a separate detection device for detecting the state position of one or more suction elements relative to the work roll.

[0190] When one or more suction elements are positioned relative to the coating roll on the side opposite the outlet nozzle of the coating device, excessive overspray can be removed particularly effectively from around the work roll.

[0191] Favorable efficiencies can be cumulatively or alternatively achieved using this coating apparatus if the coating apparatus has a mixing device for mixing particles with respect to hard phase particles and matrix particles, and the mixing device has an additional measuring device for measuring hard phase and / or matrix components, and the additional measuring device has one or more sensor elements.

[0192] Another measuring device in the coating apparatus can be advantageously positioned in a mixing apparatus and / or a dispensing apparatus for providing particles, such as a powder conveyor.

[0193] It is also advantageous if the coating device has a processing device that performs grinding or subtraction operations, thereby allowing the substrate and / or wear protection layer to be processed, particularly before and / or after the wear protection layer is applied.

[0194] The efficiency of this coating apparatus can also be advantageously achieved or improved by equipping the coating apparatus with a processing device that performs grinding and / or subtraction operations, thereby better preparing the substrate or the wear-protective layer already present therein for particle coating.

[0195] Furthermore, a new wear protection layer applied to the substrate can be post-treated by a subtractive processing device, particularly a subtractive processing device having a grinding subtractive processing device and / or a device for selective laser melting.

[0196] The coating apparatus includes a feeding device for feeding the substrate to the processing position, a rotating device for rotating the substrate at the processing position, and / or a removal device for removing the work roll from the processing position. When the feeding device, rotating device, and removal device operate together semi-automatically or preferably fully automatically, a high degree of automation can be achieved in this coating apparatus, and therefore high efficiency can be guaranteed.

[0197] It is also advantageous if the coating apparatus includes a cooling and / or cleaning device, and the cooling and / or cleaning device has one or more nozzle elements including a nozzle opening.

[0198] The cooling and / or cleaning effects of the coating rolls achieved by this alone can significantly improve efficiency in terms of adhesion.

[0199] Advantageously, one or more nozzle elements having nozzle openings are adjustable with respect to their state position relative to the work roll, thereby enabling different cooling effects on the work roll depending, for example, on the outlet temperature of the high-temperature gas flow carrying the particles.

[0200] For example, the cooling or cleaning device may be equipped with 2 to 4 nozzle elements and can be positioned in various ways relative to the work roll in space using a manipulator.

[0201] It is advantageous when the distance between the work roll and the nozzle element or its nozzle opening is 2 mm or more, preferably 5 mm or more, particularly preferably 10 mm or more, and / or 250 mm or less, preferably 150 mm or less, particularly preferably 100 mm or less.

[0202] Such distances can also be adjusted depending on the characteristics of the base of the corresponding work roll, such as its size and mass.

[0203] Depending on the distance, additional cooling effects can also be adjusted with respect to the work roll, for example, by an airflow that acts more strongly or weakly on the work roll, and the airflow can flow along the surface of the work roll, particularly with respect to its substrate or wear protection layer.

[0204] In particular, to allow for additional temperature control when thermally applying particles, the nozzle opening can also be positioned at a distance from the work roll depending on the available cooling capacity.

[0205] It has become clear that a distance of 15mm to 50mm is generally very suitable for most applications.

[0206] In this case, the effect of particle deflection becomes greater the shorter the distance, but as the distance increases, the cooling effect on the work roll usually decreases significantly.

[0207] In particular, it has been shown that smaller work rolls are critically heated more rapidly during the thermal spraying process than larger work rolls, and therefore, cooling is advantageous, especially for smaller work rolls.

[0208] If the work roll can be properly cooled, the risk of the coating process being interrupted due to overheating of the work roll can be reduced.

[0209] Overall, good cooling of the work rolls enables more consistent process control, which in turn results in a qualitatively higher layer structure for the wear protection layer.

[0210] Generally, interruptions reduce the economic efficiency of this method.

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

[0212] In either case, the adhesion force of particles on the work roll and, consequently, the efficiency of the method or the coating apparatus can be advantageously improved by a cooling and / or cleaning device, and by further modifications of the method for cleaning the substrate and / or optionally the abrasively pre-treated wear protection layer made possible thereby.

[0213] The same applies to the cooling of the substrate by a cooling device and / or a cleaning device. If the work roll can be cooled in connection with this method, this can also advantageously improve the adhesion force of particles on the work roll and, therefore, the efficiency of this method or the coating apparatus.

[0214] In order to ensure uniform particle feeding in a coating apparatus, it is advantageous if the coating apparatus has a supplying device for providing particles, and the supplying device is set to transport particles with a transport tolerance of + / - 2g per minute with respect to the transport volume.

[0215] As already mentioned above, it is advantageous if the coating apparatus is equipped with one or more dispensing devices, and if different detection and / or measuring devices can be placed on the dispensing devices.

[0216] Therefore, in order to utilize a uniform amount of particles for thermal coating or thermal spraying, it is essential that the particles are reliably conveyed, especially at the outlet nozzle of the coating apparatus.

[0217] In this regard, it has become clear that a maximum conveying tolerance of + / - 2g per minute is advantageous in order to create a particularly uniform wear protection layer on the work rolls.

[0218] In this case, the transport tolerance may differ upward or downward depending on the amount of particles effectively transported.

[0219] In particular, the dispensing device can be configured in the form of a powder conveyor appropriately designed for transporting powdered particle mixtures.

[0220] Needless to say, individual components of a coating apparatus, particularly detection devices, measuring devices, cooling and / or cleaning devices, and / or sieving devices, can be manually adjusted to suit their respective work rolls.

[0221] However, it is advantageous if the related equipment can be automatically adjusted based on process parameters, such as data relating to the substrate and / or wear protection layer.

[0222] Furthermore, it is advantageous if the supplying equipment, particularly the powder conveyor, is configured to preheat the conveyed particles or mixture of conveyed particles using the thermal energy generated by the coating equipment (e.g., an HVOF burner or HVAF burner).

[0223] For example, preheating such particles can influence their melting behavior or liquefaction in a high-temperature gas flow.

[0224] It should also be noted that it is advantageous if the thermal energy generated by the coating device is used cumulatively to reduce the residual moisture content of the particle mixture.

[0225] It is also advantageous when the thermal energy generated by the coating device is cumulatively used to preheat the substrate of the work roll.

[0226] However, a preferred embodiment of this modification is intended to be a coating apparatus equipped with an open-loop control and / or closed-loop control device, wherein the open-loop control and / or closed-loop control device is configured to automatically open-loop or close-loop control one or more devices of the coating apparatus, particularly in a mutually dependent manner.

[0227] Such open-loop and / or closed-loop control devices allow for the automatic control of the operation of one or more devices, thereby further advantageously influencing the adhesion force.

[0228] To that extent, open-loop control and / or closed-loop control devices are particularly advantageous if they operate in response to data detected, such as at least one of the detection devices, at least one of the measuring devices, cooling and / or cleaning devices, sieving devices and / or other supplying devices, feeding devices, rotating devices and / or removal devices.

[0229] Clearly, the efficiency of this coating apparatus can be advantageously achieved or further enhanced by appropriately configured open-loop and / or closed-loop control devices.

[0230] Therefore, open-loop control and / or closed-loop control devices are particularly suitable when they are configured such that, while the particles are thermally applied to the work roll, more than 50% of the particles adhere to and remain on the substrate and / or the already applied abrasion protection layer.

[0231] Open-loop control and / or closed-loop control devices are particularly advantageous when configured such that 60% or more, preferably 75% or more, and especially preferably 80% or more of the particles adhere to and remain on the substrate and / or the already applied abrasion protection layer.

[0232] The coating apparatus can operate particularly efficiently when the open-loop control and / or closed-loop control devices are set so that 40% or less, preferably 25% or less, and especially preferably 20% or less, of the particles that bounce back from the substrate and / or already applied wear protection layer while the particles are thermally coated onto the work rolls.

[0233] To that extent, open-loop and / or closed-loop control devices for controlling a coating apparatus in an open-loop and / or closed-loop manner are particularly advantageous for carrying out methods according to the features described herein.

[0234] In particular, the method according to the present invention can be carried out particularly efficiently by a coating apparatus operating in this manner.

[0235] Further advantageous efficiency improvements in terms of improving the adhesion force of particles to the work roll can be achieved by selecting the size (dimensions) of the work roll, the mass of the work roll, the substrate material, and / or the manufacturing method of the substrate.

[0236] Preferably, the coating apparatus has a thickness control configured to measure the thickness of the wear protection layer, in particular a real-time thickness control, and in particular a permanent thickness control.

[0237] This allows the coating apparatus to be advantageously controlled in open-loop and / or closed-loop manner in terms of achieving the desired thickness of the wear protection layer.

[0238] Other advantages, details, and features of the present invention will become even more apparent from the exemplary embodiments described below. [Brief explanation of the drawing]

[0239] [Figure 1] This is a schematic diagram of possible procedures for manufacturing or repairing work rolls, with respect to multiple method options, some of which are optional. [Figure 2] This is a schematic diagram of a coating apparatus for applying particles to a work roll, which can perform the method or procedure shown in Figure 1. [Modes for carrying out the invention]

[0240] As illustrated in Figure 1, a first possible procedure I for automatically manufacturing or repairing a work roll 100 (see Figure 2) for rolling a metal material (not shown) is illustrated.

[0241] It should be noted here that variations of this method are not shown or explained separately using other diagrams of the procedure.

[0242] To that extent, the individual processes can be changed in order or combined with each other.

[0243] On the one hand, each step can be arbitrary, and on the other hand, the procedure shown merely as an example can be supplemented by other steps or variations thereof that are not explicitly shown herein.

[0244] The exemplary method shown in Figure 1 begins with a first step 1, which includes providing a base 102 for a work roll 100 at a starting point 1.

[0245] This could be a newly manufactured work roll 100 having an unused base 102, or a work roll 100 to be repaired having a used base 2 including a wear protection layer 104.

[0246] In either case, at starting point 1, the particles 112 can be applied to the work roll 100 automatically by a coating device 110 (see Figure 2) for thermally applying or spraying the particles 112 onto the surface 104 of the work roll 100, i.e., without manual intervention by an operator.

[0247] The procedure illustrated and described herein ensures that more than 65% of the particles 112 sprayed in the direction of the work roll 100 adhere to the work roll 100, thereby enabling the method to be carried out very efficiently.

[0248] After the substrate 102 is provided to or fed into the processing position 116 of the coating device 110, the substrate 102 is cleaned according to step 2.

[0249] According to step 3, the substrate 102 is measured to detect the actual values ​​of the substrate 102 and, if applicable, the old wear protection layer 104 already present thereon.

[0250] According to step 4, the detected actual value can be automatically compared with the target value.

[0251] Next, according to step 5, the processing and coating parameters can be automatically detected according to the detected actual values.

[0252] According to step 6, the substrate 102 can be automatically preheated to, for example, 110°C if necessary.

[0253] If this is a work roll 100 that needs repair, according to the intermediate process 6A, first, the existing old wear protection layer 104 can be automatically ground, for example, by automatically performing partial layer removal, thereby automatically homogenizing and regenerating the entire old wear protection layer 104, or in some cases, automatically removing it completely from the base 102.

[0254] Subsequently, the appropriately processed base body 102 can be preheated as needed according to step 6.

[0255] According to step 7, the residual moisture content is automatically measured and, if necessary, automatically reduced to a value of 7%.

[0256] According to step 8, in this case, the particles 112 can be preheated automatically.

[0257] According to step 9, the particles 112 are automatically pre-screened, resulting in a variety of particles having particle sizes ranging from 10 μm to 25 μm.

[0258] According to step 10, the particles 112 are automatically mixed to obtain a desired particle mixture 112A consisting of hard phase particles and matrix particles, with the hard phase component making up 65%.

[0259] According to step 11, the particle mixture 112A is automatically preheated to a usable temperature that can be set to, for example, about 60°C.

[0260] According to step 12, the particles 112 are thermally coated or sprayed as a particle mixture 112A onto a rotating work roll 100 at the processing position 116 with an adhesion force of, for example, more than 65%.

[0261] According to step 13, the outlet velocity of the particle mixture 112A that exits the outlet nozzle 122 of the coating device 110 as a high-temperature gas stream 120 is automatically measured and, if necessary, automatically adjusted to, for example, approximately 1050 m / sec.

[0262] According to step 14, the outlet temperature of the particle mixture 112A is automatically measured and, if necessary, automatically adjusted to, for example, approximately 900°C.

[0263] According to step 15, the overspray 126 is automatically sucked up from the area 130 around the work roll 100, preferably at a suction speed of 22 m / s.

[0264] According to step 16, the work roll 100 is automatically cooled.

[0265] According to step 17, the wear protection layer 104 is automatically post-treated, for example, by the EDT method.

[0266] According to step 18, the wear protection layer 104 is inspected automatically, for example, optically.

[0267] According to process 19, the manufactured work rolls 100 are automatically labeled and registered.

[0268] According to step 20, a preliminary sample is automatically generated.

[0269] According to process 21, the manufactured work roll 100 is automatically removed from the processing position and provided for further use.

[0270] To that extent, the procedure described in the example, which began at starting point 1, ends at step 21, which represents the procedure's ending point 21.

[0271] Here, the procedure can be started from the beginning at starting point 1, and the procedure can be performed similarly or with modifications.

[0272] As already mentioned above, the individual steps can be combined almost arbitrarily, performed several times or as desired, or omitted.

[0273] Next, as shown in Figure 2, a first possible exemplary embodiment of a coating apparatus 110 for coating particles 112 as a particle mixture 112A onto the surface 102A of the base 102 of the work roll 100 is shown.

[0274] In this case, the coating device 110 has a mechanical direction 132 in which the particle mixture 112A is applied to the work roll 100.

[0275] The coating apparatus 110 has a processing position 116 in which a work roll 100 is rotatably supported by a rotating device 136 around a rotating axis 136A for thermally coating particles 112. As shown in Figure 2, the direction of rotation 136B is indicated.

[0276] The coating device 110 has a feed device 138 (shown only schematically) which includes a feed position 138A, and the base 102 of the designated work roll 100 is fed from the feed position to the processing position 116 in the feed direction 138B.

[0277] The coating device 110 further includes a removal device 140 (shown only schematically) which includes a removal position 140A, and the manufactured work roll 100 is removed from the processing position 116 to this removal position in the removal direction 140.

[0278] In this exemplary embodiment, the coating apparatus 110 also includes a processing apparatus 144 (shown schematically) that performs grinding and / or subtraction operations, which can be used to process the substrate 102 and / or the wear protection layer 104 as needed.

[0279] To generate a high-temperature gas flow 120, the coating apparatus 110 has a burner device 146, and the particles 112 are carried out by the high-temperature gas flow 120 from the outlet nozzle 122 of the coating apparatus 110 in the machine direction 132.

[0280] In this case, the burner device 146 can be designed in various ways, for example, as an HVOF burner.

[0281] The coating device 110 has a dispensing device 150 so that particles 112 or powdered particle mixture 112A can be reliably supplied to the burner device 146 and provided there in sufficient quantities.

[0282] In this case, the supplying device 150 is positioned particularly above the burner device 146 in relation to the burner device 146 and 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 sieving device 150C for sieving particles 112 or particle mixture 112A.

[0283] With respect to the particles 112 or the powdered particle mixture 112A, more precisely, the coating device 110 is equipped with a first detection device 152, the sensor element (not shown herein) capable of detecting the residual moisture content of the particles 112 or the powdered particle mixture 112A, so that the particles 112 can be adjusted to the most optimal residual moisture content possible before being supplied to the burner device 146 or its outlet nozzle 122.

[0284] In this case, the sensor element is provided in the supply device 150.

[0285] In this case, the high residual moisture content can be reduced as needed by the thermal energy generated by the burner device 146.

[0286] In particular, the function of the coating apparatus 110 in the sense of the present invention can be controlled by the detected residual moisture content value.

[0287] In order to allow the coating apparatus 110 to confirm the particle size of the particles 112 or the powder particle mixture 112A, the coating apparatus 110 has a separate detection device 154, the sensor element of which (not shown herein) can detect the particle size with respect to the particles 112 or the powder particle mixture 112A.

[0288] In particular, in this invention, the function of the coating apparatus 110 in the sense of this invention can be controlled by the detected particle size value.

[0289] Furthermore, in order to enable measurement of the exit velocity of the particles 112 at the exit nozzle 122 as well, the coating device 110 also has a measuring device 156 for measuring the exit velocity.

[0290] For this purpose, the measuring device 156 has one or more sensor elements (not shown) that can measure the exit velocity at the exit nozzle 122 or in the region 158 behind it.

[0291] In particular, the function of the coating device 110 in the sense of the present invention can also be operated based on the detected exit velocity value.

[0292] Furthermore, in order to enable measurement of the exit temperature of the particles 112 or the hot gas stream 120 at the exit nozzle 122 as well, the coating device 110 has another measuring device 160 for measuring the exit temperature.

[0293] The other measuring device 160 also has one or more sensor elements (not shown) that can measure the exit temperature at the exit nozzle 122 or in the region 158 behind it.

[0294] In particular, the function of the coating device 110 in the sense of the present invention can also be operated based on the detected exit temperature value.

[0295] Furthermore, the coating device 110 further comprises a suction device 162 having one or preferably a plurality of suction elements (not explicitly shown here) including a suction opening (not explicitly shown here), and this suction device can suck up the overspray 126 from around the working roll 100, or particularly from the processing position 116.

[0296] The state position of the suction device 162 or its suction elements is adjustable with respect to the working roll 100 or, to that extent, with respect to the rotation axis 136A.

[0297] For this purpose, the coating device 110 or the suction device 162 has a separate detection device 164 that can detect this state position.

[0298] If the suction device 162 or its suction element is located on the opposite side 166 from the outlet nozzle 122, the overspray 126 can be particularly advantageously kept away from the work roll 100.

[0299] Furthermore, the functions of the coating apparatus 110 in the sense of the present invention can be further controlled by the detected state position value.

[0300] Cumulatively, if the coating device 110 or the mixing device 150B already described above has an additional measuring device 168 for measuring hard phase components and / or matrix components, the functions of the coating device 110 can be operated in a purposeful manner.

[0301] For this purpose, the additional measuring device 168 preferably has one or more sensor elements (not expressly shown) located in the providing device 150.

[0302] Furthermore, the coating device 110 further includes a cooling and / or cleaning device 170 that can cool or clean the work roll 100, the base body 102, or the wear protection layer 104 as needed.

[0303] For this purpose, the cooling and / or cleaning device 170 has a nozzle element (not shown in detail) that includes a nozzle opening that is adjustable with respect to the state position relative to the work roll 100.

[0304] In this case, each state position can be detected by the observation device 172.

[0305] In particular, the determined state position value allows for advantageous operation of the coating apparatus 110 in the sense of the present invention.

[0306] To better harmonize and evaluate the individual functions of the coating device 110 and enable open-loop control or closed-loop control, the coating device 110 has an upper-level open-loop control and / or closed-loop control device 174.

[0307] Here, it is further mentioned that all electrical, data technology, or other connection lines, interfaces, etc. are not explicitly shown for the sake of clarity.

[0308] In any case, using the coating device 110 illustrated and described herein, more than 65% of the particles 112 sprayed in the direction of the working roll 100 successfully adhere to the working roll 100, thereby enabling the coating device 110 and the method implemented thereby to be extremely efficient.

Explanation of Signs

[0309] I Procedure 1 Starting point or first step (providing) 2 Second step (cleaning) 3 Third step (measuring) 4 Fourth step (comparing values) 5 Fifth step (determining processing parameters) 6 Sixth step (preheating the substrate) 6A Alternative sixth step (grinding process) 7 Seventh step (reducing the residual moisture rate) 8 Eighth step (preheating the particles) 9 Ninth step (pre-screening) 10 Tenth step (mixing) 11 Eleventh step (preheating the particle mixture) 12 Twelfth step (thermally applying) 13 Thirteenth step) (detecting the exit speed) 14 Fourteenth step (detecting the exit temperature) 15 Fifteenth step (absorbing overspray) 16. Step 16 (Cooling the work roll) 17. Step 17 (Post-processing) 18. Step 18 (Inspection) 19. Step 19 (Registration) 20. Step 20 (Preliminary Sample) 21. Step 21 (Removal) 100 work rolls 102 Substrate (new or used) 102A surface 104 Abrasion protection layer 110 Coating device 112 particles 112A particle mixture 116 Processing position 120 High-temperature gas flow 122 Outlet nozzle 126 Overspray 130 perimeter 132 Machine direction 136 Rotating device 136A Rotating shaft 136B Rotation direction 138 Feeder 138A Feed-in position 138B Feed direction 140 Removal device 140A Removal location 140B Removal direction 144 Processing equipment 146 Burner device 150 Providing device 150A Powder Conveyor 150B Mixing device 150C sieve device 152 Detection device 154 Another detection device 156 First measuring device 158 areas 160 Another measuring device 162 Suction device 164 yet another detection device 166 Opposite side 168 Additional measuring devices 170 Cooling and / or cleaning device 172 Observation equipment 174 Open-loop control and / or closed-loop control device

Claims

1. A method for manufacturing or repairing a work roll (100) comprising a base body (102) and an abrasion protection layer (104), wherein, in a method for thermally coating the work roll (100) with particles (112), 50% or more, preferably 60% or more, or 75% or more, and particularly preferably 80% or more of the particles (112) adhere to the base body (102) and / or the already coated abrasion protection layer (104) and remain on the base body (102) and / or the abrasion protection layer (104) during the thermal coating process.

2. The method according to claim 1, characterized in that, while the particles (112) are thermally applied, 50% or less, preferably 40% or less, or 25% or less, particularly preferably 20% or less of the particles (112) are bounced back from the substrate (102) and / or the already applied abrasion protection layer (104).

3. The method according to claim 1 or 2, characterized in that the residual moisture content of the particle mixture (112A) containing hard phase particles (112) and matrix particles (112) is 10% or less, preferably 5% or less, and particularly preferably 2% or less.

4. The method according to any one of claims 1 to 3, characterized in that the particles (112) have a particle diameter of 0.5 μm or more, preferably 1 μm or more, and / or a particle diameter of 60 μm or less, preferably 30 μm or less, and particularly preferably 15 μm or less.

5. The method according to any one of claims 1 to 4, characterized in that the particles (112) are pre-sieved to a particle size of 60 μm or less, preferably 30 μm or less, and particularly preferably 15 μm or less.

6. The method according to claim 5, characterized in that the particles (112) are screened in advance in the coating apparatus (110) before being added to the high-temperature gas flow (120) of the coating apparatus (110).

7. The method according to any one of claims 1 to 6, characterized in that the particles (112) at the outlet nozzle (122) of the coating device (110), or behind the outlet nozzle, have an outlet velocity of 500 m / s or more, preferably 800 m / s or more, particularly preferably 900 m / s or more, and / or an outlet velocity of 1500 m / s or less, preferably 1200 m / s or less, particularly preferably 1000 m / s or less.

8. The method according to claim 7, characterized in that the outlet velocity is measured at a location or region (158) located at a distance of 100 mm or less, preferably 50 mm or less, and particularly preferably 10 mm or less from the outlet nozzle (122).

9. The method according to any one of claims 1 to 8, characterized in that the particles (112) are carried out from an outlet nozzle (122) of a coating device (110) by a high-temperature gas flow (120), the particles (112) and / or the high-temperature gas flow (120) have an outlet temperature of 800°C or higher, preferably 1000°C or higher, particularly preferably 1200°C or higher, and / or the particles (112) and / or the high-temperature gas flow (120) have an outlet temperature of 2200°C or lower, preferably 2000°C or lower, particularly preferably 1800°C or lower.

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

11. The method according to claim 9 or 10, characterized in that the outlet temperature is measured at a location or region (158) located at a distance of 100 mm or less, preferably 50 mm or less, and particularly preferably 10 mm or less from the outlet nozzle (122).

12. The method according to any one of claims 1 to 11, characterized in that, while the particles (112) are applied to the work roll (100), an overspray (126) surrounding the work roll (100), which includes at least particles (112) that are not attached to the substrate (102), process gas, combustion products, etc., is sucked up from the periphery (130) of the work roll (100) at a suction speed of 10 m / s or more, preferably 15 m / s or more, particularly preferably 18 m / s or more, and / or at a suction speed of 30 m / s or less, preferably 25 m / s or less, particularly preferably 20 m / s or less.

13. The method according to claim 12, characterized in that, in order to suck up the overspray (126), at least one suction opening of the suction device (162) is positioned at a distance of 0.1 m or more, preferably 0.2 m or more, and / or at a distance of 1.5 m or less, preferably 1 m or less, and particularly preferably 0.5 m or less from the work roll (100).

14. The method according to claim 12 or 13, characterized in that the distance between the work roll (100) and the suction opening is adjusted according to the suction speed.

15. The method according to any one of claims 12 to 14, characterized in that the suction speed and / or the distance between the substrate (102) and the suction opening is adjusted according to the outlet speed of the particles (112) at or behind the outlet nozzle of the coating device (110).

16. The method according to any one of claims 1 to 15, characterized in that, with respect to a particle mixture (112A) containing hard phase particles (112) and matrix particles (112), the proportion of the hard phase is adjusted to 50% or more, preferably 55% or more, particularly preferably 60% or more, and / or the proportion of the hard phase is adjusted to 90% or less, preferably 85% or less, particularly preferably 80% or less.

17. The method according to any one of claims 1 to 16, characterized in that, before applying the particles (112), the substrate (102) is preheated to a substrate temperature of 30°C or higher, preferably 50°C or higher, particularly preferably 60°C or higher, and / or a substrate temperature of 120°C or lower, preferably 150°C or lower, particularly preferably 200°C or lower.

18. The method according to any one of claims 1 to 17, characterized in that the substrate (102) or the wear protection layer (104) already disposed on the substrate is ground and / or subtracted before and / or during the application of the particles (112) to the work roll (100).

19. The method according to claim 18, characterized in that, before and / or during the application of the particles (112) to the work roll (100), the wear protection layer (104) is removed in at least a portion and / or part of its area.

20. The method according to claim 18 or 19, characterized in that an old wear protection layer (104) already placed on the substrate (102) is processed by a subtractive process, and then the particles (112) are applied to the processed old wear protection layer (104).

21. The method according to any one of claims 1 to 20, characterized in that the wear protection layer (104) is post-treated in particular by the EDT method (discharge texturing method).

22. The method according to any one of claims 1 to 21, characterized in that the substrate (102) is provided semi-automatically or automatically to a coating apparatus (110) according to any one of claims 32 to 48.

23. The method according to claim 22, characterized in that the substrate (102) is automatically measured, an actual value is detected therefrom, and in particular the detected actual value is compared with a target value.

24. The method according to claim 22 or 23, characterized in that at least one coating parameter is automatically detected according to the detected actual value.

25. The method according to claims 22 to 24, characterized in that the substrate (102) is automatically preheated to the substrate temperature described in claim 17, in particular, according to the detected actual value.

26. The method according to any one of claims 22 to 25, characterized in that the wear protection layer (104) applied to the substrate (102) is automatically inspected, and in particular optically inspected.

27. The method according to any one of claims 22 to 26, characterized in that the manufactured work roll (100) is automatically labeled and registered by, for example, a barcode, an RFID chip, etc.

28. The method according to any one of claims 22 to 27, characterized in that a preliminary sample is automatically generated.

29. The method according to any one of the prior claims, characterized in that the new wear protection layer (104) applied to the substrate (102) is processed by a subtractive machining method, particularly grinding, and / or by a selective laser melting method.

30. A work roll (100) for rolling metal products, particularly for rolling thin metal strips, having a base body (102) and an abrasion protection layer (104), characterized in that the work roll (100) is manufactured by the method described in any one of claims 1 to 29.

31. A rolling stand for processing metal products such as thin metal strips, comprising the work roll (100) described in claim 30.

32. A thin metal strip rolled using the work roll (100) described in claim 30, and moreover, cold-rolled.

33. A coating apparatus (110), particularly a thermal coating apparatus (110), for coating particles (112) onto a base (102) of a work roll (100), comprising a burner device (146), particularly an HVOF burner (high-speed oxygen fuel burner) and / or an HVAF burner (high-speed air fuel burner), wherein the coating apparatus (110) is configured such that, while thermally coating the work roll (100) with the particles (112), 50% or more of the particles (112) adhere to the base (102) and / or an already applied abrasion protection layer (104) and remain on the base (102) and / or the abrasion protection layer (104).

34. The coating apparatus (110) is configured such that 60% or more, preferably 75% or more, and particularly preferably 80% or more of the particles (112) adhere to the substrate (102) and / or the already applied abrasion protection layer (104) and remain on the substrate (102) and / or the already applied abrasion protection layer (104), as described in claim 33.

35. The coating apparatus (110) according to claim 33 or 34, characterized in that, while the coating apparatus (110) is thermally applied to the work roll (100), 40% or less, preferably 25% or less, and particularly preferably 20% or less of the particles (112) are repelled from the substrate (102) and / or the already applied abrasion protection layer (104).

36. The coating apparatus (110) has a detection device (152) for detecting the residual moisture content of a particle mixture (112A) comprising hard phase particles (112) and matrix particles (112), and the detection device (152) has one or more sensor elements arranged in a dispensing device (150) for providing the particle mixture (112A), as described in any one of claims 33 to 35.

37. The coating apparatus (110) has a sieving device (150C) for sieving the particles (112) according to their particle size, and the sieving device (150C) is characterized in that it has one or more sieving elements arranged in a supplying device (150) for providing the particles (112), as described in any one of claims 33 to 36.

38. The coating apparatus (110) according to any one of claims 33 to 37, wherein the coating apparatus (110) has a separate detection device (154) for detecting particle size, and the separate detection device (154) has, in particular, one or more sensor elements arranged in a supplying device (150) for providing the particles (112).

39. The coating apparatus (110) is further comprising a measuring device (156) for measuring the outlet velocity of the particles (112) at an outlet nozzle (122), and the measuring device (156) is characterized in that it has one or more sensor elements capable of measuring the outlet velocity at or behind the outlet nozzle, according to any one of claims 33 to 38.

40. The coating apparatus (110) is further comprising a measuring device (160) for measuring the outlet temperature of the particles (112) at the outlet nozzle (122), wherein the measuring device (160) has one or more sensor elements capable of measuring the outlet temperature at or after the outlet nozzle, as described in any one of claims 33 to 39.

41. The coating apparatus (110) is further comprising a suction device (162) for sucking up overspray (126) containing at least particles (112), process gas, combustion products, etc., that are not adhering to the substrate (102), from around the substrate (102) (130), wherein the suction device (162) comprises one or more suction elements having suction openings that are adjustable in particular with respect to the state position of the suction device relative to the work roll (100), as described in any one of claims 33 to 40.

42. The coating apparatus (110) according to claim 41, characterized in that the suction device (162) has another detection device (164) for detecting the state position of one or more suction elements relative to the work roll (100).

43. The coating apparatus (110) according to claim 41 or 42, characterized in that the one or more suction elements are arranged on the opposite side (166) from the outlet nozzle (122) of the coating apparatus (110) with respect to the coating roll (100).

44. The coating apparatus (110) has a mixing apparatus (150B) for mixing hard phase particles (112) and matrix particles (112), the mixing apparatus (150B) has an additional measuring apparatus (168) for measuring hard phase components and / or matrix components, the additional measuring apparatus (168) has one or more sensor elements arranged in a dispensing apparatus (150), such as a powder conveyor (150A), in particular for dispensing the mixing apparatus (150B) and / or the particles (112), as described in any one of claims 33 to 43.

45. The coating apparatus (110) is characterized in that it has a processing apparatus (144) that performs grinding or subtracting operations and can process the substrate (102) and / or the wear protection layer (104), as described in any one of claims 33 to 44.

46. The coating apparatus (110) comprises a feeding device (138) for feeding the substrate (102) to a processing position (116), a rotating device (136) for rotating the substrate (102) at the processing position (116), and / or a removal device (140) for removing the work roll (100) from the processing position (116), wherein the feeding device (138), the rotating device (136), and the removal device (140) operate together semi-automatically or preferably fully automatically, as described in any one of claims 33 to 45.

47. The coating apparatus (110) according to any one of claims 33 to 46, wherein the coating apparatus (110) has a cooling and / or cleaning apparatus (170), and the cooling and / or cleaning apparatus (170) has one or more nozzle elements including a nozzle opening that is adjustable in particular with respect to the state position of the work roll (100).

48. The coating apparatus (110) has a dispensing device (150) for providing particles (112), and the dispensing device (150) is set to transport the particles (112) with a transport tolerance of + / - 2 g / min with respect to the transport amount, as described in any one of claims 33 to 47.

49. An open-loop control and / or closed-loop control device of the coating apparatus (110) according to any one of claims 33 to 48, characterized in that the open-loop control and / or closed-loop control device is set to automatically control 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 coating apparatus (110) in a particularly interdependent manner, thereby enabling open-loop control or closed-loop control automatically.

50. The coating apparatus (110) according to any one of claims 33 to 49, characterized in that it has a layer thickness control set to measure the layer thickness of the wear protection layer (104), in particular a layer thickness control that proceeds in real time, and in particular a layer thickness control that is performed permanently.

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