Multimaterial Roll Hot Working for Large Wear-Resistant Rolls
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Solution Overview
Problem
Current technologies face challenges in producing large, high-quality multimaterial rolls with excellent wear resistance and adhesion, particularly for rolls over 3 meters in length, due to limitations in manufacturing methods such as hot isostatic pressing and spray forming.
Innovation Solution
A method for manufacturing multimaterial rolls that involves creating a multimaterial starting ingot using suitable methods like casting, welding, or powder metallurgy, followed by hot working to achieve the desired length and properties, ensuring excellent adhesion and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If centrifugal casting is used to produce multimaterial rolls with higher alloyed tool steel working surface, then adhesion between materials is improved, but homogeneity and carbide size optimization cannot be achieved
Solution Approach 1:
The manufacturing process is divided into distinct sequential stages: first producing the base material layer through centrifugal casting, then adding the higher alloyed tool steel working surface layer separately. This segmentation allows each layer to be optimized independently for its specific requirements while maintaining strong interlayer adhesion.
Solution Approach 2:
The base material layer is prepared in advance through centrifugal casting before the higher alloyed tool steel is added. This preliminary action creates a prepared substrate with good adhesion properties that receives the final working surface layer, ensuring both strong bonding and optimal carbide distribution in the final product.
2Reliability
If powder metallurgy or spray forming is used to increase alloying content, then wear resistance and lifetime are improved, but manufacturing cost increases
Solution Approach 1:
Higher alloyed tool steel is applied specifically to the working surface layer where wear resistance is most critical, while the base material uses lower alloyed steel. This local quality approach ensures optimal wear protection exactly where needed without unnecessarily increasing alloy content and cost throughout the entire roll structure.
Solution Approach 2:
The roll is constructed as a composite material structure combining lower alloyed base material with higher alloyed tool steel working surface. This composite approach leverages the cost-effectiveness of lower alloyed steel for the bulk structure while incorporating expensive high-performance materials only where they provide the most value for wear resistance and lifetime.
3Reliability
If higher alloyed special materials are used in working surface, then wear resistance is improved, but material cost increases
Solution Approach 1:
Higher alloyed special materials are concentrated in the working surface layer where they directly contact and process the material being rolled, providing wear resistance exactly where it is most heavily utilized. The base material and non-contact areas use more economical lower alloyed steel, optimizing the cost-performance ratio.
Solution Approach 2:
The alloying level parameter is varied through the roll structure - higher alloy content in the working surface layer for maximum wear resistance, and lower alloy content in the base material for cost efficiency. This parameter gradient optimizes both performance and economic factors.
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 method enables the production of high-quality multimaterial rolls with improved wear resistance and adhesion, specifically for large rolls, by optimizing the microstructure and carbide distribution, thus enhancing the durability and performance of the rolls.
Implementation Method 1
the multimaterial starting ingot is hot worked so, that the desired length and properties are achieved
Data Source
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Figure 2a~2c
Figure 3a~3c
AI summary
In the present there is presented a method to manufacture multimaterial rolls (1), comprising method to produce base material (B) containing part of the roll, joining of special material (A) containing part for that, hot working at least part of the length of the roll ingot (1') containing base material (B) and special material (A), so that at least requested roll ingot (1') length (Lv') and diameter (Hv') are achieved as well as final treatment of the roll ingot (1') to manufacture finished roll (1). This method enables manufacture of large rolls (1), for example having length more than 3 meters as one integrated component without welding or mechanical joint so, that in the working surfaces (2) of the rolls (1) is used steel with high amount of alloying elements and carbide forming alloying elements.