CN114393372A - Preparation method of forged steel composite roller - Google Patents
Preparation method of forged steel composite roller Download PDFInfo
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- CN114393372A CN114393372A CN202111569704.7A CN202111569704A CN114393372A CN 114393372 A CN114393372 A CN 114393372A CN 202111569704 A CN202111569704 A CN 202111569704A CN 114393372 A CN114393372 A CN 114393372A
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- 239000002131 composite material Substances 0.000 title claims abstract description 61
- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 24
- 239000010959 steel Substances 0.000 title claims abstract description 24
- 238000002360 preparation method Methods 0.000 title claims abstract description 7
- 238000003466 welding Methods 0.000 claims abstract description 41
- 238000000034 method Methods 0.000 claims abstract description 32
- 238000010438 heat treatment Methods 0.000 claims abstract description 26
- 238000001816 cooling Methods 0.000 claims abstract description 18
- 238000005242 forging Methods 0.000 claims abstract description 18
- 238000001514 detection method Methods 0.000 claims abstract description 17
- 238000010894 electron beam technology Methods 0.000 claims abstract description 17
- 230000001681 protective effect Effects 0.000 claims abstract description 9
- 238000004806 packaging method and process Methods 0.000 claims abstract description 7
- 239000013589 supplement Substances 0.000 claims abstract description 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical group [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 12
- 238000004140 cleaning Methods 0.000 claims description 12
- 229910000851 Alloy steel Inorganic materials 0.000 claims description 10
- 229910052786 argon Inorganic materials 0.000 claims description 6
- 239000002184 metal Substances 0.000 claims description 6
- 230000001502 supplementing effect Effects 0.000 claims description 6
- 229910045601 alloy Inorganic materials 0.000 abstract description 24
- 239000000956 alloy Substances 0.000 abstract description 24
- 238000004519 manufacturing process Methods 0.000 abstract description 23
- 239000000654 additive Substances 0.000 abstract description 2
- 230000000996 additive effect Effects 0.000 abstract description 2
- 239000011162 core material Substances 0.000 description 16
- 239000000047 product Substances 0.000 description 6
- 230000001276 controlling effect Effects 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 238000005096 rolling process Methods 0.000 description 5
- 238000009750 centrifugal casting Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 238000005299 abrasion Methods 0.000 description 3
- 238000009749 continuous casting Methods 0.000 description 2
- 238000001746 injection moulding Methods 0.000 description 2
- 238000004321 preservation Methods 0.000 description 2
- 241000566150 Pandion haliaetus Species 0.000 description 1
- 238000010923 batch production Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000000875 corresponding effect Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000005204 segregation Methods 0.000 description 1
- 238000009718 spray deposition Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- Forging (AREA)
Abstract
The invention discloses a preparation method of a forged steel composite roller, belonging to the field of additive manufacturing of high-alloy composite rollers, and the method comprises the following steps: combining the clean mandrel and the roller sleeve into a combined blank on the outer surface of the low-alloy mandrel and the inner surface of the high-alloy roller sleeve; preheating the combined blank in a preheating furnace with protective atmosphere and preserving heat; the combined blank is placed on a welding trolley; performing heat supplement on the combined blank in a vacuum chamber, simultaneously vacuumizing, and performing electron beam welding on the combined blank; packaging the combined blank by an electron gun, and controlling the combined blank to be cooled at a preset cooling speed; carrying out flaw detection and repair welding on the welding seam to form a composite roller; heating in a heating furnace; forging is carried out on a large forging machine. The invention adopts the low alloy core shaft to provide high toughness for the roller, adopts the high alloy roller sleeve to ensure the wear resistance of the working layer, and reduces the manufacturing difficulty and saves the production cost by assembling and welding the core shaft and the roller sleeve.
Description
Technical Field
The invention relates to the field of additive manufacturing of high-alloy composite rolls, in particular to a preparation method of a forged steel composite roll.
Background
In the field of steel rolling, a roller is used as a main consumption piece of a rolling mill, and the consumption cost is about 5-10% of the steel rolling cost. The quality of the roller not only relates to the steel rolling cost and the operation rate of the rolling mill, but also influences the quality of rolled materials to a great extent. In order to meet the requirement that the roller is in service for a long time in severe environments such as high temperature, high abrasion, strong load, radioactivity and the like, the roller core and the roller neck of the roller are ideal to have high toughness, the working layer is high in abrasion resistance, and a single material cannot meet the requirements of high abrasion resistance and high toughness at the same time. Meanwhile, along with the increase of the specification of the roller, the uniformity and the deformability of the internal structure of the roller are poorer, and the problems of loose core, inclusion and alloy segregation are more serious; the high alloy roller has high integral alloy content, only the working layer part is used, and the core material with high alloy content does not have corresponding effect completely, thereby causing resource waste; the high alloy content results in high production cost of the roller, which results in high price of the roller and is not favorable for market competition.
Composite rolls are a common method of reducing the core alloy content. The currently used methods for producing composite rolls include four methods: centrifugal Casting (CF), continuous casting composite (CPC), electroslag remelting (ESR), and spray forming (Osprey). The centrifugal casting method has the characteristics of high production efficiency and low cost, but the bonding strength of the inner layer and the outer layer is low, so that the centrifugal casting method is mainly used for preparing hot roll products; the continuous casting composite method has high internal and external bonding strength and low production cost, but has more complex production equipment and production process and low production efficiency, and is not beneficial to batch production; the product produced by the electroslag remelting method has less impurities and low production cost, but the equipment has high cost and low production efficiency, and the grain structure of the composite interface is coarse, so the composite effect is not ideal; the working layer of the injection molding method has fine crystal grains and good composite effect of a bonding surface, but the production cost is high, the production period is long, the injection thickness of the working layer is limited, and the injection molding method is not suitable for large-size products.
Therefore, it is necessary to develop a roll, which can reduce the manufacturing difficulty and the production cost on the premise of ensuring the high wear resistance of the outer layer and the high toughness of the core part of the roll.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a method for preparing a forged steel composite roller, which reduces the manufacturing difficulty and the production cost on the premise of ensuring the high wear resistance of the outer layer of the roller and the high toughness of the core part.
In order to solve the technical problems, the technical scheme adopted by the invention is as follows:
a preparation method of a forged steel composite roller comprises the following steps:
s1, cleaning the outer surface of the mandrel and the inner surface of the roller sleeve on high-speed surface cleaning equipment to enable fresh metal to be completely exposed on the surface;
s2, combining the clean core shaft and the roller sleeve into a combined blank on an automatic assembly device;
s3, automatically overturning the combined blank, conveying the combined blank to a preheating furnace with protective atmosphere, preheating and preserving heat until the combined blank is at the uniform temperature;
s4, hoisting the combined blank after temperature equalization to a buffer mechanism in front of an electron beam welding machine, and slowly lowering the combined blank onto a welding trolley;
s5, starting a heat supplementing system in the vacuum chamber to supplement heat for the combined blank, simultaneously vacuumizing, and performing electron beam welding on the combined blank when the preset pressure is reached;
s6, completing packaging of the combined blank through an electron gun, and controlling the packaged combined blank to be cooled at a preset cooling speed;
s7, detecting the flaw of the welding seam, completing repair welding, and forming a composite roller;
s8, conveying the composite roller to a forge piece heating furnace for heating;
and S9, forging the heated composite roller on a large forging machine.
The technical scheme of the invention is further improved as follows: s1, the mandrel is made of low alloy steel, and the roller sleeve is made of high alloy steel.
The technical scheme of the invention is further improved as follows: in S3, the protective atmosphere is argon.
The technical scheme of the invention is further improved as follows: in S3, the preheating temperature range is 50-200 ℃.
The technical scheme of the invention is further improved as follows: in S5, the preset pressure is 0.05 Pa.
The technical scheme of the invention is further improved as follows: in S6, the cooling mode of the packaged combined blank is furnace cooling, and the preset cooling speed is not more than 20 ℃/h.
The technical scheme of the invention is further improved as follows: in S7, a phased array flaw detector is used for flaw detection.
The technical scheme of the invention is further improved as follows: in S8, the heating temperature range is 1100-1250 ℃, and the heating time is 4-10 h.
The technical scheme of the invention is further improved as follows: in S9, upsetting is carried out on the composite roller to realize the initial combination of the interface, then after the composite roller is turned over for 90 degrees, the roller surface is forged and drawn to a preset size, and the composite interface is enabled to realize firm metallurgical combination.
Due to the adoption of the technical scheme, the invention has the technical progress that:
1. according to the invention, through reasonably utilizing the difference of the outer layer and the core part of the roller on the performance requirements, the low-alloy core shaft and the high-alloy roller sleeve are innovatively assembled and welded, the low-alloy roller shaft provides high toughness for the roller, and the high-alloy roller sleeve ensures the wear resistance of the working layer.
2. According to the process method, on the premise of ensuring the high wear resistance of the outer layer of the roller and the high strength and toughness of the core part, the large structural part is produced by adopting the preparation method of the forged steel composite roller, the effect of realizing metallurgical bonding of the shaft and sleeve composite interface is realized, and the manufacturing difficulty and the production cost are reduced.
3. The composite roller produced by the process method has the advantages that the shaft sleeve binding layer is subjected to flaw detection without interface reflection, and the effect of metallurgical bonding is achieved.
Drawings
FIG. 1 is a flow chart of the manufacturing method of the forged steel composite roll of the present invention.
Detailed Description
The invention is described in further detail below with reference to the following figures and examples:
as shown in fig. 1, a method for preparing a forged steel composite roll comprises the following steps:
s1, cleaning the outer surface of a mandrel made of low alloy steel and the inner surface of a roller sleeve made of high alloy steel on high-speed surface cleaning equipment to completely expose fresh metal;
the low alloy steel is alloy steel with the total amount of alloy elements less than 5 percent, and the high alloy steel is alloy steel with the alloy elements more than 10 percent; the low alloy roll shaft provides high toughness for the roll, and the high alloy roll sleeve ensures the wear resistance of the working layer.
S2, combining the clean core shaft and the roller sleeve on an automatic assembly device to form a combined blank;
s3, automatically overturning the combined blank, conveying the combined blank to a preheating furnace with a protective atmosphere of argon by a travelling crane, and preserving heat at the temperature of 50-200 ℃ until the combined blank is at the uniform temperature;
the heat preservation time is related according to the specification of the combined blank, and the combined blank needs to be guaranteed to be uniform in the heat preservation time.
S4, hoisting the combined blank after temperature equalization to a buffer mechanism in front of an electron beam welding machine, and slowly lowering the combined blank onto a welding trolley;
s5, starting a heat supplementing system in the vacuum chamber to supplement heat for the combined blank, avoiding the influence of heat dissipation of the combined blank on welding temperature, simultaneously vacuumizing, and performing electron beam welding on the combined blank when the preset pressure is up to 0.05 Pa;
the temperature of the electron beam welding depends on the materials of the mandrel and the sleeve.
S6, completing packaging of the combined blank through an electron gun, performing furnace cooling on the combined blank, and controlling the packaged combined blank to be cooled at a preset cooling speed, wherein the preset cooling speed is not more than 20 ℃/h, so that the welding seam is prevented from cracking;
s7, flaw detection is carried out on the welding seam by adopting a phased array flaw detector, repair welding is completed, and a composite roller is formed;
s8, conveying the composite roller to a forge piece heating furnace for heating, wherein the heating temperature range is 1100-1250 ℃, and the heating time is 4-10 h;
s9, forging the heated composite roller on a large-scale forging machine, upsetting the composite roller to realize the initial combination of the interface, turning over for 90 degrees, forging and drawing the roller surface to a preset size to realize firm metallurgical combination of the composite interface; the preset size is drawn up according to the design size of the composite roller.
Example 1
S1, cleaning the outer surface of a mandrel made of 42CrMo and the inner surface of a roller sleeve made of Cr5 forged steel on high-speed surface cleaning equipment to completely expose fresh metal;
s2, combining the clean core shaft and the roller sleeve on an automatic assembly device to form a combined blank;
s3, automatically overturning the combined blank, conveying the combined blank to a preheating furnace with a protective atmosphere of argon by a travelling crane, and preserving heat for 6 hours at the temperature of 50 ℃ until the combined blank is at the uniform temperature;
s4, hoisting the combined blank after temperature equalization to a buffer mechanism in front of an electron beam welding machine, and slowly lowering the combined blank onto a welding trolley;
s5, starting a heat supplementing system in the vacuum chamber to supplement heat for the combined blank, simultaneously vacuumizing, and performing electron beam welding on the combined blank when preset pressure of 0.05Pa is reached, wherein the electron beam welding temperature is not lower than 3000 ℃;
s6, completing packaging of the combined blank through an electron gun, performing furnace cooling on the combined blank, and controlling the packaged combined blank to be cooled at a preset cooling speed of 20 ℃/h;
s7, flaw detection is carried out on the welding seam by adopting a phased array flaw detector, repair welding is completed, and a composite roller is formed;
s8, conveying the composite roller to a forge piece heating furnace for heating, wherein the heating temperature is 1200 ℃, and the heating time is 7 hours;
s9, forging the heated composite roller on a large forging machine, upsetting the composite roller to realize the initial combination of the interface, then turning over for 90 degrees, forging and drawing the roller surface to a preset size, wherein the diameter of the roller body is 500mm, the length of the roller body is 1050mm, and the total length of the roller is 2400 mm.
Flaw detection is carried out on the product combined layer according to the flaw detection standard of the national standard JB/T4120-2017, the flaw detection result is qualified, and the use requirement of a user is met.
Example 2
S1, cleaning the outer surface of a mandrel made of 42CrMo and the inner surface of a roller sleeve made of Cr5 forged steel on high-speed surface cleaning equipment to completely expose fresh metal;
s2, combining the clean core shaft and the roller sleeve on an automatic assembly device to form a combined blank;
s3, automatically overturning the combined blank, conveying the combined blank to a preheating furnace with a protective atmosphere of argon by a travelling crane, and preserving heat for 6 hours at the temperature of 150 ℃ until the combined blank is at the uniform temperature;
s4, hoisting the combined blank after temperature equalization to a buffer mechanism in front of an electron beam welding machine, and slowly lowering the combined blank onto a welding trolley;
s5, starting a heat supplementing system in the vacuum chamber to supplement heat for the combined blank, simultaneously vacuumizing, and performing electron beam welding on the combined blank when preset pressure of 0.05Pa is reached, wherein the electron beam welding temperature is not lower than 3000 ℃;
s6, completing packaging of the combined blank through an electron gun, performing furnace cooling on the combined blank, and controlling the packaged combined blank to be cooled at a preset cooling speed of 10 ℃/h;
s7, flaw detection is carried out on the welding seam by adopting a phased array flaw detector, repair welding is completed, and a composite roller is formed;
s8, conveying the composite roller to a forge piece heating furnace for heating, wherein the heating temperature is 1100 ℃, and the heating time is 4 hours;
s9, forging the heated composite roller on a large forging machine, upsetting the composite roller to realize the initial combination of the interface, then turning over for 90 degrees, forging and drawing the roller surface to a preset size, wherein the diameter of the roller body is 450mm, the length of the roller body is 900mm, and the total length of the roller is 2050 mm.
Flaw detection is carried out on the product combined layer according to the flaw detection standard of the national standard JB/T4120-2017, the flaw detection result is qualified, and the use requirement of a user is met.
Example 3
S1, cleaning the outer surface of a mandrel made of 42CrMo and the inner surface of a roller sleeve made of Cr3 forged steel on high-speed surface cleaning equipment to completely expose fresh metal;
s2, combining the clean core shaft and the roller sleeve on an automatic assembly device to form a combined blank;
s3, automatically overturning the combined blank, conveying the combined blank to a preheating furnace with a protective atmosphere of argon by a travelling crane, and preserving heat for 6 hours at the temperature of 200 ℃ until the combined blank is at the uniform temperature;
s4, hoisting the combined blank after temperature equalization to a buffer mechanism in front of an electron beam welding machine, and slowly lowering the combined blank onto a welding trolley;
s5, starting a heat supplementing system in the vacuum chamber to supplement heat for the combined blank, simultaneously vacuumizing, and performing electron beam welding on the combined blank when preset pressure of 0.05Pa is reached, wherein the electron beam welding temperature is not lower than 3000 ℃;
s6, completing packaging of the combined blank through an electron gun, performing furnace cooling on the combined blank, and controlling the packaged combined blank to be cooled at a preset cooling speed of 10 ℃/h;
s7, flaw detection is carried out on the welding seam by adopting a phased array flaw detector, repair welding is completed, and a composite roller is formed;
s8, conveying the composite roller to a forge piece heating furnace for heating, wherein the heating temperature is 1250 ℃, and the heating time is 10 hours;
s9, forging the heated composite roller on a large forging machine, upsetting the composite roller to realize the preliminary combination of an interface, then overturning for 90 degrees, forging and drawing the roller surface to a preset size, wherein the diameter of the roller body is 600mm, the length of the roller body is 1550mm, and the total length of the roller is 2750 mm.
Flaw detection is carried out on the product combined layer according to the flaw detection standard of the national standard JB/T4120-2017, the flaw detection result is qualified, and the use requirement of a user is met.
The specific material and the upper and lower limit values and interval values of the process parameters (such as temperature, time and the like) can realize the invention, and the embodiments are not listed.
In conclusion, the invention reasonably utilizes the difference of the outer layer and the core part of the roller on the performance requirements, innovatively adopts the low-alloy core shaft and the high-alloy roller sleeve to be assembled and welded, the low-alloy roller shaft provides high toughness for the roller, the high-alloy roller sleeve ensures the wear resistance of the working layer, the effect of realizing metallurgical bonding of the composite interface of the shaft and the sleeve is realized, the manufacturing difficulty is reduced, and the production cost is saved.
Claims (9)
1. A preparation method of a forged steel composite roller is characterized by comprising the following steps: the method comprises the following steps:
s1, cleaning the outer surface of the mandrel and the inner surface of the roller sleeve on high-speed surface cleaning equipment to enable fresh metal to be completely exposed on the surface;
s2, combining the clean core shaft and the roller sleeve into a combined blank on an automatic assembly device;
s3, automatically overturning the combined blank, conveying the combined blank to a preheating furnace with protective atmosphere, preheating and preserving heat until the combined blank is at the uniform temperature;
s4, hoisting the combined blank after temperature equalization to a buffer mechanism in front of an electron beam welding machine, and slowly lowering the combined blank onto a welding trolley;
s5, starting a heat supplementing system in the vacuum chamber to supplement heat for the combined blank, simultaneously vacuumizing, and performing electron beam welding on the combined blank when the preset pressure is reached;
s6, completing packaging of the combined blank through an electron gun, and controlling the packaged combined blank to be cooled at a preset cooling speed;
s7, detecting the flaw of the welding seam, completing repair welding, and forming a composite roller;
s8, conveying the composite roller to a forge piece heating furnace for heating;
and S9, forging the heated composite roller on a large forging machine.
2. The method for preparing the forged steel composite roll according to claim 1, wherein the method comprises the following steps: s1, the mandrel is made of low alloy steel, and the roller sleeve is made of high alloy steel.
3. The method for preparing the forged steel composite roll according to claim 1, wherein the method comprises the following steps: in S3, the protective atmosphere is argon.
4. The method for preparing the forged steel composite roll according to claim 1, wherein the method comprises the following steps: in S3, the preheating temperature range is 50-200 ℃.
5. The method for preparing the forged steel composite roll according to claim 1, wherein the method comprises the following steps: in S5, the preset pressure is 0.05 Pa.
6. The method for preparing the forged steel composite roll according to claim 1, wherein the method comprises the following steps: in S6, the cooling mode of the packaged combined blank is furnace cooling, and the preset cooling speed is not more than 20 ℃/h.
7. The method for preparing the forged steel composite roll according to claim 1, wherein the method comprises the following steps: in S7, a phased array flaw detector is used for flaw detection.
8. The method for preparing the forged steel composite roll according to claim 1, wherein the method comprises the following steps: in S8, the heating temperature range is 1100-1250 ℃, and the heating time is 4-10 h.
9. The method for preparing the forged steel composite roll according to claim 1, wherein the method comprises the following steps: in S9, upsetting is carried out on the composite roller to realize the initial combination of the interface, then after the composite roller is turned over for 90 degrees, the roller surface is forged and drawn to a preset size, and the composite interface is enabled to realize firm metallurgical combination.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115194422A (en) * | 2022-06-01 | 2022-10-18 | 中钢集团邢台机械轧辊有限公司 | Method for forging composite roller |
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