The working environment of the parts of metallurgical equipment in steel plants is mostly high temperature, high variable load, alternating hot and cold, corrosion, wear and fatigue conditions. Various types of rolls, conveying rolls, and supporting rolls are prone to corrosion and wear, and require regular replacement and maintenance.
When producing and processing metal sheets, the surface quality of various rolls is extremely high. For these parts with large usage and high maintenance frequency, it is crucial to further effectively improve service life and reduce maintenance costs for the development of the industry. Currently, the surface protective layer of steel metallurgical equipment parts is mostly prepared by electroplating, thermal spraying, arc welding and other methods.
The application of laser cladding technology can more effectively improve the service life of part coatings, reduce maintenance links, and have greater flexibility in regulating coating thickness and coating performance.
Problem Insight
Rolls are the most important consumables for equipment in the steel industry. The quality of the rolls directly affects the efficiency and product quality of the rolling mill, so there are high technical requirements for surface treatment.
Rolls bear tremendous pressure and friction during the rolling process, and their surfaces are prone to wear, cracks, and even peeling. Typically, the failure modes of rolls include thermal cracking, peeling, fatigue wear, abrasive wear, etc.Currently, electroplating is mostly used for the preparation and maintenance of surface corrosion-resistant coatings for rollers.
Due to the low bonding strength, easy cracking, short service life, and frequent need for disassembly and maintenance from underground, the installation workload is large and the cycle is long. Therefore, the maintenance cost is high and the delayed construction period is very long.
Laser Cladding With Roll Solutions
Laser cladding technology can solve these pain points. It can repair the surface wear of the roll, restore its size and surface performance. According to the material, working environment, and technical requirements of the roll, the corresponding cladding alloy powder and cladding process are selected.
The cladding layer achieves good metallurgical bonding with the substrate, and the cladding layer has a dense structure, which plays a good strengthening role. In addition, laser cladding technology has a small heat input and will not cause repair resistance due to the large and hard heat-affected zone of the substrate.
The surface hardness of the coating is evenly distributed and will not cause scratches to the steel plate due to local hardness. The wear resistance and impact resistance of the repaired roll surface are several times higher than those of traditional repair processes.
Our laser cladding solution
1）We generally provide steel mills to customers with the following solutions: a set of 6000W laser cladding machine, a robot, a rotary table.
2）we will provide customized solutions according to the actual needs of customers, such as adding vertical workbenches, robot crawler floors, etc.
Advantage of our solution
a) Rolls can be repaired repeatedly using laser cladding technology, while electroplating and thermal spraying cannot.
b) Labor costs have been saved by 50%.
c) We are a manufacturer and main parts are manufactured by ourselves.
Case study
While working with Indian customers, we encountered a challenging problem. The customer uses our laser cladding equipment to process their rolls, however the roll material is ductile iron. When the traditional cladding process is applied to rolls made of this material, it will cause the rolls to crack, which undoubtedly brings great trouble to customers’ production.
To solve this problem, our engineers conducted in-depth testing and research. After unremitting efforts, engineers came up with an innovative solution: first add a layer of primer powder, and then use iron-based powder for cladding. This solution has achieved excellent results in practical applications. The roll showed no cracking and the hardness reached 58HRC, fully meeting the customer’s requirements.
This successful case fully demonstrates the professional capabilities and innovative spirit of our team. We are not only able to provide high-quality laser cladding equipment, but also provide practical solutions to different materials and problems. Through cooperation with Indian customers, we have accumulated valuable experience and laid a solid foundation for dealing with similar problems in the future. At the same time, this case also proves our strength and credibility to customers and wins us more market opportunities.
After-sales services
After the equipment acceptance, the laser source quality assurance period is 2 years, and other components are 1 year.
The supplier provides lifelong maintenance services for the machine and provides daily consultation and guidance on equipment at any time.
During the quality assurance period, the supplier is responsible for free replacement of parts and services for any damage or damage caused by the quality of the equipment itself, except for routine consumables (optical fibers, protective lenses, nozzles, etc.) and accidents that belong to the user’s illegal operation responsibility.
Outside the quality assurance period, the supplier still provides buyers with necessary technical support and preferential consumables and parts supply.
The supplier promises to inform users of software upgrades in a timely manner and provide free software upgrade services.
Our laser machines have been delivered to Turkey, Brazil, Chile, India, Vietnam, Thailand, Australia and they have processed lots of rolls. We can share more videos and technical details if you are interested.