Aluminum Bronze Roller for Continuous Casting Wear Reduction
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Solution Overview
Problem
Rollers for continuous casting plants with build-up welded iron alloy layers experience excessive wear and instability near the mold, leading to non-round running and accelerated wear, making them unsuitable for guiding and supporting strands, especially in areas requiring high stability.
Innovation Solution
A roller with a multiphase heterogeneous aluminum bronze layer, containing Al > 10% by mass, is build-up welded to the base body, creating a strong connection, improving temperature transfer and distribution, corrosion resistance, and mechanical strength through martensitic phases, and optionally incorporating Ni, Fe, and Mn for enhanced properties, with recesses for uniform temperature and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a build-up welded iron alloy layer is applied to the roller base body, then the hardness and mechanical strength of the roller is improved, but the roller experiences excessive wear and instability near the mold
Solution Approach 1:
The patent changes the chemical composition parameters of the aluminum bronze layer, specifically setting Al content to 7-12%, Si content to 2-4%, and Mn content to 1-3%, which creates a multiphase structure that simultaneously provides hardness and stability near the mold
Solution Approach 2:
The patent creates a composite structure with a base body made of ductile iron or steel and a build-up welded layer of multiphase aluminum bronze, combining the advantages of both materials to achieve high mechanical strength and improved reliability near the mold
2Object-affected harmful factors
If the aluminum bronze layer contains high Al content (>10% by mass), then corrosion resistance is improved through oxide film formation, but thermal conductivity may be reduced
Solution Approach 1:
The patent optimizes the Al content to 7-12% (with preferred range 9-11%) and incorporates Si (2-4%) and Mn (1-3%) to achieve the right balance between corrosion resistance through oxide film formation and maintaining sufficient thermal conductivity for continuous casting operations
3Strength
If the build-up welding creates a heterogeneous multiphase alloy structure, then mechanical resistance and strength are improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent controls the chemical composition parameters (Al: 7-12%, Si: 2-4%, Mn: 1-3%) to naturally form a desirable multiphase structure during build-up welding, achieving high mechanical resistance without requiring complex post-welding heat treatment or additional processing steps
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a stable roller capable of withstanding high mechanical and thermal loads, reducing wear by over 80% and maintaining stability near the mold, while ensuring effective corrosion resistance and thermal conductivity, thus improving the operational lifespan and performance of continuous casting rolls.
Implementation Method 1
bonded via a build-up weld connection (6) to the base body (2)
Implementation Method 2
the comparatively high Al content of this heterogeneous multi-phase alloy (with Al > 10% by mass) can form a firmly adhering and well-protecting oxide film (containing Cu 2 O and Al 2 O 3)
Implementation Method 3
improved temperature transfer between the layer and the base body due to dilution
Implementation Method 4
the multi-phase alloy can also lead to martensitic phases (β′, β′ 1 and/or γ′ 1 ) due to the heat treatment by build-up welding
Implementation Method 5
heat treatment by build-up welding
Data Source
Figure 1~2
Figure 3~4
AI summary
The roller has base (2) made of iron material and copper alloy layer (3) which forms a rolling surface (4) for strand (5). The layer is integrally bonded to the base through a welding joint (6). An independent claim is included for method for producing roller.