Wear-Resistant Roller Carbide Gradient Welding Beads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wear-resistant rollers for crushing particulate materials face challenges with high-pressure applications, as studded technologies are expensive and inadequate, while hardfacing lacks gripping capability and requires frequent re-welding, leading to decreased crushing effectiveness and increased downtimes.
Innovation Solution
A wear-resistant roller with welding beads composed of a higher fraction of carbide material in overlapping volumes than non-overlapping volumes, combined with Nickel or Cobalt alloys, providing enhanced wear resistance and an autogenous wear layer for improved retention and longevity, using Plasma Transfer Arc welding to concentrate carbide material in overlapping regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hardfacing is applied to the roller surface, then wear resistance and pressure resistance are improved, but gripping capability deteriorates due to surface smoothness
Solution Approach 1:
The patent applies different material compositions to different regions of the wear surface. The overlapping volumes contain higher carbide content (higher wear resistance) while the non-overlapping volumes have lower carbide content (better gripping). This local differentiation allows each region to optimize its function - the overlapping regions provide durable wear protection while the non-overlapping regions maintain surface texture for gripping capability.
2Ease of operation
If studded technology is used to improve gripping capability, then surface structure is improved, but cost and reliability under high pressure deteriorate
Solution Approach 1:
Instead of using discrete studs, the patent changes the material composition parameter continuously across the surface. By varying the carbide fraction in the welding beads, the surface creates a gradient of wear resistance and gripping characteristics. This parametric approach achieves the gripping function through surface topology rather than discrete mechanical elements, maintaining pressure resistance.
3Ease of manufacture
If uniform welding beads are applied across the surface, then manufacturing simplicity is improved, but wear resistance deteriorates due to lack of optimized carbide distribution
Solution Approach 1:
The patent introduces dynamic variation in the welding process by changing the carbide fraction parameter along the welding path. The welding parameters are dynamically adjusted so that overlapping regions receive higher carbide content while non-overlapping regions receive lower carbide content. This dynamic approach maintains manufacturing simplicity while achieving optimized wear resistance distribution.
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 enhances wear resistance and grinding efficiency by maintaining a structured surface, increasing the service life of the roller and reducing the need for frequent re-welding, with the autogenous wear layer protecting the expensive wear surface and optimizing retention for specific crushed materials.
Implementation Method 1
welding a second welding bead partially overlapping a first welding bead thereby re-heating an overlapping volume of the first welding bead
Implementation Method 2
using Plasma Transfer Arc welding to concentrate carbide material in overlapping regions
Data Source
Figure 1~2
Figure 3a~3b
Figure 4a~4b
AI summary
The invention relates to a wear-resistant roller (1) for crushing of particulate material, such as crude ore for use in the cement or minerals industry comprising a roller body (2), a wear surface (3) on the roller body (2). The wear surface (3) comprises welding beads (4) comprising a primary fraction of carbide material and a secondary fraction of material selected from the group consisting of Nickel, Nickel alloys, mixtures of Nickel and Nickel alloys and mixtures of Nickel containing refractory hard materials, Cobalt, Cobalt alloys, mixtures of Cobalt and Cobalt alloys and mixtures of Cobalt containing refractory hard materials. Furthermore, the welding beads (4) are welded to the roller body (2) in an overlapping manner such that two neighbouring welding beads (4) comprise an overlapping volume (5) and a non-overlapping volume (6), the overlapping volume (5) being an intersection volume between the two neighbouring overlapping welding beads (4), and the fraction of carbide material being higher in the overlapping volume (5) than in the non-overlapping volume (6) such that the overlapping volume (5) has a higher wear resistance compared to the non-overlapping volume (6) having a lower wear-resistance. Also the invention relates to a method of forming such a wear surface on a roller body (2).