Steel mill single-tooth roller laser cladding repair processing

In the steel industry, the durability and efficiency of equipment are key factors in production benefits. Particularly in hot and cold rolling steel production lines, various roller components such as single-tooth rollers, due to long-term use under high temperatures, high variable loads, alternating cold and heat, corrosion, wear, and fatigue conditions, their wear and failure become bottlenecks that constrain production efficiency. Traditional repair methods like turning and grinding often serve only as "remedial measures" and struggle to fundamentally address the wear issues of roller components. However, with the introduction and application of laser cladding technology, roller repair in steel mills has witnessed a revolutionary breakthrough, with laser cladding repair of single-tooth rollers becoming a hot topic in the industry.

In steel mills, single-tooth rollers, as critical components of the production line, directly impact the rolling quality of steel and production efficiency. However, during use, due to prolonged friction and compression from rolled materials, the surface of single-tooth rollers experiences severe wear, which affects their gripping force and service life. Traditional repair methods often fail to achieve ideal results, while laser cladding technology, with its unique advantages, has become the ideal choice for single-tooth roller repair.

The process of laser cladding repair for single-tooth rollers first involves surface pretreatment to remove impurities such as oil, rust, and old coatings, ensuring a strong bond between the cladding layer and the base material. Then, based on the operational requirements and material characteristics of the single-tooth roller, suitable cladding materials are selected, such as nickel-based, cobalt-based, iron-based alloys, or ceramic materials. These materials offer excellent wear resistance, corrosion resistance, and heat resistance, meeting the demands of single-tooth rollers in harsh working environments.

During the cladding process, the laser beam scans and melts the surface of the single-tooth roller at a constant power and spot diameter. The cladding material rapidly melts under the laser beam and forms a metallurgical bond with the base material. Due to the rapid cooling characteristics of laser cladding, the cladding layer has a fine microstructure and a small heat-affected zone, effectively avoiding issues like thermal deformation and thermal fatigue damage. Additionally, laser cladding can be automated, significantly improving repair efficiency and precision.

After laser cladding repair, the surface performance of single-tooth rollers is significantly enhanced. The cladding layer exhibits excellent wear resistance, corrosion resistance, and heat resistance, effectively resisting friction and compression from rolled materials and extending the service life of the single-tooth roller. Furthermore, laser cladding repair can address local defects on the surface of single-tooth rollers, such as cracks and spalling, improving their overall strength and stability.

In practical applications, the effectiveness of laser cladding repair for single-tooth rollers has been widely recognized. A large steel enterprise, after adopting laser cladding technology for single-tooth roller repair, saw a significant increase in service life, extending from a few months to over a year. At the same time, the repaired single-tooth rollers demonstrated improved gripping force and stability during the rolling process, thereby enhancing the rolling quality of steel and production efficiency.

Beyond single-tooth rollers, laser cladding technology can also be applied to the repair of other roller components, such as work rolls, conveyor rolls, and backup rolls. These roller components also play vital roles in steel production, and their performance directly impacts steel quality and production efficiency. Through laser cladding repair, the service life of these roller components can be effectively extended, their wear and corrosion resistance improved, thereby reducing production costs and enhancing production efficiency.

Additionally, laser cladding technology can be applied to equipment repair and surface modification in other fields. For example, in the aerospace industry, laser cladding can be used to repair critical components like engine blades and turbine disks; in automotive manufacturing, it can repair shaft parts such as crankshafts and camshafts; in mold manufacturing, it can enhance the wear resistance and service life of molds. These applications fully demonstrate the broad prospects of laser cladding technology in equipment repair and surface modification.

However, the application of laser cladding technology also faces some challenges. For instance, the cost of laser cladding equipment is high, requiring significant investment for purchase and maintenance; the operational requirements for laser cladding technology are demanding, necessitating technicians with extensive experience and skills; moreover, precise control of parameters such as cladding materials, laser power, and spot diameter is required during the laser cladding process to ensure the quality and performance of the cladding layer. Therefore, when applying laser cladding technology, enterprises need to comprehensively consider factors such as production needs, technical capabilities, and financial conditions to develop reasonable application plans and technical routes.

In summary, the application of laser cladding technology in the repair of single-tooth rollers in steel mills has brought a revolutionary breakthrough to the steel industry. It not only significantly extends the service life of single-tooth rollers and improves their wear and corrosion resistance but also reduces production costs and enhances production efficiency. With the continuous development and refinement of laser cladding technology, it is believed that its applications in the steel industry and other fields will become increasingly widespread, injecting new vitality and momentum into enterprise production and development.