Large roller surface laser quenching repair processing

Laser quenching repair processing for large roller surfaces is a crucial technology in modern industry, especially in sectors such as steel rolling, papermaking, and plastic processing, where roller performance directly impacts production efficiency and product quality. With technological advancements, laser quenching technology has gradually become the preferred method for repairing large roller surfaces due to its efficiency, precision, and environmental friendliness.

Laser Quenching Repair Process for Large Roller Surfaces

The laser quenching repair process for large roller surfaces typically includes the following steps:

1. Pre-treatment: Before laser quenching, the roller surface must undergo pre-treatment, including cleaning off oil stains and impurities to ensure surface smoothness, and applying a laser-absorbing coating to enhance laser absorption.

2. Surface Preheating: Preheating reduces thermal stress during the laser quenching process and prevents crack formation. Modern laser quenching equipment is often equipped with a preheating temperature-controlled worktable, which uses a nano-infrared ring heating coil to preheat the roller surface. The preheating temperature is generally controlled within a specific range to ensure the effectiveness of laser quenching.

3. Laser Quenching: The laser quenching device transmits high-power laser beams to scan the roller surface. Parameters such as laser spot size, shape, and scanning speed can be adjusted based on the roller material and repair requirements. During the quenching process, precise control of laser output power and quenching range is necessary to achieve the desired hardened layer depth and hardness.

4. Post-treatment: After laser quenching, the roller must undergo cooling, cleaning, and inspection. During cooling, abrupt temperature changes should be avoided to prevent thermal stress. After cleaning, testing equipment such as microhardness testers can be used to examine the hardness, depth, and microstructure of the hardened layer to ensure repair quality.

Advantages of Laser Quenching Repair for Large Roller Surfaces

Compared to traditional surface treatment technologies, laser quenching repair for large roller surfaces offers significant advantages:

1. High Efficiency: The laser quenching process is fast, enabling large-area processing in a short time, significantly improving production efficiency.

2. Precision: The strong focusing capability of laser beams allows precise control of the quenching range and depth, avoiding thermal effects on surrounding areas.

3. Environmental Friendliness: The laser quenching process does not require chemical reagents or coolants, reducing environmental pollution and wastewater treatment costs.

4. Excellent Wear Resistance: The hardened layer formed by laser quenching has a fine microstructure, high hardness, and excellent wear resistance, significantly extending the roller's service life.

5. Wide Applicability: Laser quenching technology is suitable for large rollers of various materials and shapes, including rolling mill rolls and corrugating rolls.

Application Examples

Laser Quenching Treatment for Corrugating Rolls

Corrugating rolls are critical components in papermaking machinery, and their surfaces must withstand friction and compression from paper, requiring high wear resistance. Traditional treatment methods, such as carburizing quenching and medium/high-frequency quenching, often suffer from issues like significant deformation and uneven hardness. Laser quenching technology effectively addresses these problems. By applying a phosphating solution to the teeth of the corrugating roll and using a laser to symmetrically scan the tooth tips, a dispersion strengthening effect can be achieved, significantly improving wear resistance and service life.

Laser Quenching Repair for Large Rolling Mill Rolls

Large rolling mill rolls are widely used in the steel industry, and their surfaces are prone to wear and cracks after prolonged use. Traditional repair methods, such as surfacing welding and spraying, often result in poor bonding between the repair layer and the base material, as well as uneven hardness. Laser quenching technology, by precisely controlling laser output power and scanning speed, forms a uniform hardened layer, significantly improving the roll's hardness and wear resistance. Additionally, the laser quenching process does not require extensive movement of the roll, reducing deformation and errors during repair.

Conclusion

Laser quenching repair processing for large roller surfaces is an efficient, precise, and environmentally friendly surface treatment technology with broad application prospects. Through proper pre-treatment, precise control, and post-treatment, it significantly enhances roller wear resistance and service life while reducing production costs and environmental pollution. As laser technology continues to develop and improve, its application in the field of large roller surface repair is expected to become increasingly widespread. For professionals in related industries, mastering the principles and operational methods of laser quenching technology will help improve product quality and production efficiency, injecting new vitality into enterprise development.