Composite Roll Production With Electron Beam Welded Journals
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Solution Overview
Problem
Current methods for producing highly wear-resistant composite rolls, especially for large dimensions, are inefficient and costly due to limitations in manufacturing techniques and material application processes.
Innovation Solution
The method involves attaching pins to a base body by electron beam welding after hot isostatic pressing, allowing for the use of existing large-scale systems and minimizing thermal stress on the base body, enabling the creation of highly wear-resistant composite rolls with optimized wear properties and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pins are formed in one piece with the base body or attached by fastening means, then power transmission stability is ensured, but manufacturing complexity and cost increase for large dimension rolls
Solution Approach 1:
The roll is divided into separate components (base body and pins) that are manufactured independently and then joined through welding. This allows each component to be optimized separately and simplifies manufacturing for large dimensions.
Solution Approach 2:
The mechanical fastening system is replaced with electron beam welding, which provides a strong, permanent connection without requiring complex fastening mechanisms. The welding process creates a metallurgical bond that ensures power transmission stability.
2Reliability
If working layer is applied by hot isostatic pressing, then wear resistance is improved, but thermal stress on base body increases during subsequent pin attachment
Solution Approach 1:
Conventional welding methods that generate high thermal stress are replaced with electron beam welding. The electron beam process concentrates energy in a small area and allows for precise control of heat input, minimizing thermal stress on the base body while maintaining weld integrity.
Solution Approach 2:
The welding parameters (energy concentration, heating rate, temperature control) are optimized for electron beam welding to minimize thermal stress. The process parameters are specifically adjusted to protect the already heat-treated base body from excessive thermal stress.
3Ease of manufacture
If conventional welding methods are used to attach pins, then manufacturing is simpler, but thermal stress and distortion of base body increase
Solution Approach 1:
Conventional arc welding or resistance welding is replaced with electron beam welding. While electron beam welding requires specialized equipment, the process itself is straightforward and automated, and the benefits of minimal thermal stress and distortion outweigh the equipment complexity.
Solution Approach 2:
The welding process parameters are changed from conventional methods to electron beam parameters, which include higher energy density, faster heating rates, and more precise temperature control. These parameter changes reduce thermal stress and distortion while maintaining manufacturing efficiency.
4Strength
If rolls are manufactured in one piece from forged steel, then structural integrity is improved, but adaptability to different roll dimensions and wear resistance decrease
Solution Approach 1:
The roll is segmented into the base body and working layer, which are manufactured separately and then combined through hot isostatic pressing. This allows the base body to be optimized for structural integrity while the working layer can be selected for specific wear resistance requirements.
Solution Approach 2:
The roll uses a composite structure combining the base body material with a working layer material that has superior wear resistance properties. This composite approach allows each material to be optimized for its specific function while maintaining overall structural integrity.
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
This approach allows for the efficient and cost-effective production of composite rolls with high wear resistance and extended service life, capable of withstanding high loads and suitable for large dimensions, such as those used in hot or cold strip mills.
Implementation Method 1
the pins are attached to the base body by electron beam welding
Implementation Method 2
Electron beam welding only leads to very limited local heating, so that the base body is not thermally stressed when it is welded on
Implementation Method 3
a working layer, which is applied to the base body by hot isostatic pressing of a powder
Data Source
Figure 1~3
AI summary
The invention relates to a method for producing a composite roll (1), wherein a working layer (3) is created on a main body (2) by hot-isostatic pressing of a powder. To allow even large working rolls for hot or cold strip trains to be produced, it is provided according to the invention that, after the hot-isostatic pressing of the main body (2), journals (4) are attached to the main body (2) by welding. The invention also relates to a composite roll (1) produced according to the invention.