Rolling Mill Cast Roll Sulfide Phase Lubrication
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Solution Overview
Problem
Rolling mill rolls, particularly those in the finishing train, face degradation issues due to abrasion, oxidation, and thermal fatigue, leading to frequent shutdowns and reduced productivity, as traditional materials like chilled cast iron struggle to balance wear resistance and adhesion resistance effectively.
Innovation Solution
The introduction of sulfur as a linking element into multi-component white cast iron or high chromium white cast iron microstructures to form sulfide phase particles, combined with rare earth metals, enhances the formation of hard carbides and sulfide phases, which act as lubricants and stress reducers, improving wear resistance and adhesion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If roll surface is machined to recover initial condition, then quality is maintained, but productivity decreases due to shutdowns
Solution Approach 1:
The invention applies preliminary action by incorporating sulfide inclusions and optimizing the microstructure during the casting process, so that the roll surface inherently resists degradation throughout its service life. This preliminary structural optimization prevents the need for frequent machining interventions, maintaining surface precision while extending service intervals and improving productivity.
Solution Approach 2:
The invention extends the service life of rolls by improving their degradation resistance, effectively making them more durable and less 'short-living'. This reduces the frequency of replacement or reconditioning, thereby improving productivity without sacrificing surface precision.
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 process results in rolling mill rolls with significantly improved resistance to abrasive wear, adhesion, and crack propagation, reducing the need for frequent roll exchanges and extending the rolling mill campaign with better surface finishing of products.
Implementation Method 1
sulfide phase particles, which act as lubricants and stress reducers, improving wear resistance and adhesion resistance
Implementation Method 2
The addition of at least one rare earth metal to the foundry ladle
Implementation Method 3
the material of the shield is poured into the mold and, due to the action of the centrifugal force, it is distributed uniformly over its inner surface
Data Source
AI summary
The rolling mill cast roll having a shield portion made of multi-component white iron with excellent resistance to adhesion and propagation of cracks, having a composition consisting essentially, by weight ratio, of 1.5-2.5% carbon, 3.0-10% chromium, 2.0-8.0% molybdenum, 2.0-8.0% tungsten, 2.0-10% vanadium, 0.1-0.8% sulfur, up to 2.0% manganese, wherein the manganese is balanced with said sulfur in a 2:1 ratio (Mn:S), up to 1.0% silicon, up to 1.0% of nickel, 0.1% Ce, up to 0.08% phosphorus and a sufficient amount of Fe, is produced by a centrifugal casting method.