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

Area of Science:

• Materials Science
• Manufacturing Engineering
• Mechanical Engineering

Background:

• Continuous casting rollers face failure due to cyclic stresses, thermal cycles, and corrosive environments, leading to fatigue cracking and surface peeling.
• Existing remanufacturing methods often fail to address these root causes effectively, limiting roller service life and increasing maintenance costs.

Purpose of the Study:

• To develop an improved remanufacturing process for continuous casting rollers to enhance service life and reduce repair costs.
• To design a gradient structure and novel equipment for a welding-hammering hybrid remanufacturing process.

Main Methods:

• Numerical simulation was used to analyze roller failure modes and causes.
• A gradient structure (base, transition, strengthened layers) was designed with material selection based on service conditions.
• Novel welding-hammering composite remanufacturing equipment was developed, and process parameters were optimized through experiments.

Main Results:

• Microscopic analysis revealed refined grains, reduced welding defects, and improved surface toughness in the remanufactured rollers.
• The welding-hammering hybrid process resulted in a forged structure, unlike the as-cast structure from traditional methods.
• The service life of continuous casting rollers was significantly improved by approximately 100%.

Conclusions:

• The developed welding-hammering hybrid remanufacturing process effectively addresses the failure mechanisms of continuous casting rollers.
• The gradient structure and optimized process parameters contribute to a superior forged microstructure and enhanced material properties.
• This innovative approach offers a substantial improvement in roller durability and cost-effectiveness compared to conventional techniques.