Fe-Bonded WC Cemented Carbide for Dent-Resistant Cold Rolling Rolls
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Solution Overview
Problem
Cemented carbides with Co—Ni—Cr binder phases have insufficient compressive yield strength for cold rolling of steel strips, leading to surface yielding and poor performance in rolling rolls, while Fe-based cemented carbides with high wear resistance lack sufficient compressive yield strength for cold rolling applications.
Innovation Solution
A cemented carbide composition comprising 55-90% WC particles and 10-45% Fe-based binder phase with specific elemental ratios of Ni, C, Cr, Si, W, Co, and Mn, sintered using vacuum-sintering and cooling techniques to achieve high compressive yield strength and mechanical strength, preventing surface dents during cold rolling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rolling roll with sufficient compressive yield strength is used for cold rolling, then surface quality is improved, but wear resistance may be compromised
Solution Approach 1:
The invention employs a composite material structure where WC hard particles (55-90 mass%) provide wear resistance while the Fe-based binder phase with martensitic or bainitic structure provides high compressive yield strength. This composite design ensures that the rolling roll surface maintains both the hardness needed to prevent wear and the strength needed to prevent yielding during cold rolling operations
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 cemented carbide exhibits compressive yield strength of 1200 MPa or more, allowing for continuous high-quality cold rolling of steel strips with reduced surface dents and extended roll life, while maintaining wear resistance and mechanical strength.
Implementation Method 1
the martensitic transformation of Fe provides the iron-based cemented carbide with improved hardness and strength
Implementation Method 2
sintering WC particles with Co—Ni—Cr-based binder phases
Data Source
AI summary
A cemented carbide comprising 55-90 parts by mass of WC particles, and 10-45 parts by mass of an Fe-based binder phase, the binder phase having a composition comprising 2.5-10% by mass of Ni, 0.2-1.2% by mass of C, 0.5-5% by mass of Cr, 0.2-2.0% by mass of Si, 0.1-3% by mass of W, 0-5% by mass of Co, and 0-1% by mass of Mn, the balance being substantially Fe and inevitable impurities, and the cemented carbide being substantially free from composite carbides having major axes of 5 μm or more. This cemented carbide is produced by cooling at a cooling rate of 60° C./hour or more between 900° C. and 600° C., after vacuum sintering.