Hot Rolling Roll Cladding Composition for Wear and Thermal Shock
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Solution Overview
Problem
The hot rolling process in ironworks faces increased demands for roll durability and reduced manufacturing costs due to diversified materials and higher speeds, necessitating improved durability performance and surface quality of rolls.
Innovation Solution
A roll with a cladding layer containing specific chemical compositions (0.5-1.1% C, 2.8-4.0% Si, 0.9-1.6% Cu, 2.7-3.3% Ni, 13.5-14.5% Cr, 0.8-1.1% Mo, 0.9-1.1% Co, and 0.2-0.4% Nb) and a thickness of 5 mm or more, formed using a continuous pouring process, providing enhanced mechanical strength, wear resistance, and thermal shock resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cladding layer with conventional composition is used to improve corrosion resistance, then corrosion resistance is improved, but durability under high mechanical load and thermal shock deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the chemical composition parameters of the cladding layer. Specifically, it sets C at 0.05-0.70%, Si at 2.80-4.00%, Mn at 0.50-2.00%, Cr at 13.50-14.50%, Mo at 0.80-1.10%, and Ni at 2.70-3.30%, with a thickness of 5mm or more. This optimized composition range transforms the material properties to achieve both corrosion resistance and high strength under mechanical load and thermal shock.
Solution Approach 2:
The patent uses composite materials by creating a cladding layer with a specific multi-element alloy composition on the outer circumference of the roll body. The composite structure combines multiple alloying elements (C, Si, Mn, Cr, Mo, Ni) in controlled proportions to achieve synergistic effects, providing both corrosion resistance and mechanical strength that neither element could provide alone.
2Productivity
If roll replacement frequency is decreased to reduce manufacturing cost, then manufacturing cost is reduced, but surface quality of rolled product deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-forming a thick cladding layer (5mm or more) with optimized composition during the rolling process itself. This preliminary preparation of the roll surface ensures that even after extended use and regrinding, the surface quality remains high enough for continued production, thereby reducing replacement frequency while maintaining product quality.
3Reliability
If cladding layer thickness is increased to improve durability, then wear resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the cladding layer formation process with the existing rolling process by applying the cladding layer to the outer circumference of the roll body in a integrated manufacturing step. This combination approach allows for the production of rolls with thick cladding layers (5mm or more) without significantly increasing manufacturing complexity, as the process is incorporated into the standard production workflow.
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 roll exhibits superior durability, allowing extended use and regrinding, with improved high-temperature hardness and resistance to corrosion and seizing, reducing the frequency of roll replacement and enhancing manufacturing efficiency.
Implementation Method 1
excels at wear resistance, seizing resistance, thermal shock resistance, high-temperature oxidation resistance property
Implementation Method 2
excels at wear resistance, seizing resistance, thermal shock resistance, high-temperature oxidation resistance property
Data Source
AI summary
[PROBLEM] The invention provides a roll for hot rolling process having various types of more excellent durability performances than conventional rolls, and provides also a method for manufacturing the same.[SOLUTION] A cladding layer 4 is formed on an outer circumference portion of a roll for hot rolling process 1, where the cladding layer 4 comprises: 0.5 to 0.7% by mass of C, 2.8 to 4.0% by mass of Si, 0.9 to 1.1% by mass of Cu, 1.4 to 1.6% by mass of Mn, 2.7 to 3.3% by mass of Ni, 13.5 to 14.5% by mass of Cr, 0.8 to 1.1% by mass of Mo, 0.9 to 1.1% by mass of Co, and 0.2 to 0.4% by mass of Nb, with a balance being Fe and inevitable impurities, and has a thickness of 5 mm or more.