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Gradient Structure Design and Welding-Hammering Hybrid Remanufacturing Process of Continuous Casting Rollers

To improve the service life and reduce the repair cost of continuous casting rollers, a new welding-hammering hybrid remanufacturing process in which the roller was designed with a gradient structure was proposed, and corresponding equipment was developed. First, the failure modes and their causes f...

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Autores principales: Zhang, Jiansheng, Xiao, Guiqian, Peng, Jie, Yu, Yingyan, Zhou, Jie
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9738101/
https://www.ncbi.nlm.nih.gov/pubmed/36500084
http://dx.doi.org/10.3390/ma15238588
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author Zhang, Jiansheng
Xiao, Guiqian
Peng, Jie
Yu, Yingyan
Zhou, Jie
author_facet Zhang, Jiansheng
Xiao, Guiqian
Peng, Jie
Yu, Yingyan
Zhou, Jie
author_sort Zhang, Jiansheng
collection PubMed
description To improve the service life and reduce the repair cost of continuous casting rollers, a new welding-hammering hybrid remanufacturing process in which the roller was designed with a gradient structure was proposed, and corresponding equipment was developed. First, the failure modes and their causes for a continuous casting roller were analyzed by numerical simulation. The cyclic tension–compression shear stress, cyclic tension–compression normal stress, thermal cycle, and highly corrosive environment caused fatigue cracking and overall peeling of the roller surface. Second, the gradient structure composed of a base layer, transition layer, and strengthened layer of a continuous casting roller was designed, and materials for each layer were selected according to their different service conditions. Third, novel equipment for continuous welding-hammering composite remanufacturing was developed, and the optimized process parameters were obtained through welding experiments. Finally, an application test was carried out; the microscopic analysis showed that refined grains, fewer welding defects, and better surface toughness were obtained. Compared with traditional remanufacturing processes without hammering, the welding-hammering hybrid process achieved a forged structure instead of as-cast structure, which significantly improved the service life of the continuous casting roller by about 100%.
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spelling pubmed-97381012022-12-11 Gradient Structure Design and Welding-Hammering Hybrid Remanufacturing Process of Continuous Casting Rollers Zhang, Jiansheng Xiao, Guiqian Peng, Jie Yu, Yingyan Zhou, Jie Materials (Basel) Article To improve the service life and reduce the repair cost of continuous casting rollers, a new welding-hammering hybrid remanufacturing process in which the roller was designed with a gradient structure was proposed, and corresponding equipment was developed. First, the failure modes and their causes for a continuous casting roller were analyzed by numerical simulation. The cyclic tension–compression shear stress, cyclic tension–compression normal stress, thermal cycle, and highly corrosive environment caused fatigue cracking and overall peeling of the roller surface. Second, the gradient structure composed of a base layer, transition layer, and strengthened layer of a continuous casting roller was designed, and materials for each layer were selected according to their different service conditions. Third, novel equipment for continuous welding-hammering composite remanufacturing was developed, and the optimized process parameters were obtained through welding experiments. Finally, an application test was carried out; the microscopic analysis showed that refined grains, fewer welding defects, and better surface toughness were obtained. Compared with traditional remanufacturing processes without hammering, the welding-hammering hybrid process achieved a forged structure instead of as-cast structure, which significantly improved the service life of the continuous casting roller by about 100%. MDPI 2022-12-01 /pmc/articles/PMC9738101/ /pubmed/36500084 http://dx.doi.org/10.3390/ma15238588 Text en © 2022 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Zhang, Jiansheng
Xiao, Guiqian
Peng, Jie
Yu, Yingyan
Zhou, Jie
Gradient Structure Design and Welding-Hammering Hybrid Remanufacturing Process of Continuous Casting Rollers
title Gradient Structure Design and Welding-Hammering Hybrid Remanufacturing Process of Continuous Casting Rollers
title_full Gradient Structure Design and Welding-Hammering Hybrid Remanufacturing Process of Continuous Casting Rollers
title_fullStr Gradient Structure Design and Welding-Hammering Hybrid Remanufacturing Process of Continuous Casting Rollers
title_full_unstemmed Gradient Structure Design and Welding-Hammering Hybrid Remanufacturing Process of Continuous Casting Rollers
title_short Gradient Structure Design and Welding-Hammering Hybrid Remanufacturing Process of Continuous Casting Rollers
title_sort gradient structure design and welding-hammering hybrid remanufacturing process of continuous casting rollers
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9738101/
https://www.ncbi.nlm.nih.gov/pubmed/36500084
http://dx.doi.org/10.3390/ma15238588
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