Technical News

I. Core Principles of Laser Cladding Repair Processing Technology for Live Loop Rollers

Laser cladding repair is an advanced process that synchronously melts alloy, ceramic and other cladding powders with the surface substrate of the live roller through a high-energy laser beam, and rapidly solidifies them under the protection of inert gas to form a high-performance coating with metallurgical bonding. Its core advantage lies in achieving a dual effect of "repair + strengthening" : it not only restores the dimensional accuracy of the roller body but also enhances the surface performance through the cladding layer, addressing the pain points of weak adhesion and easy detachment in traditional repair.

Ii. Causes of Failure of Live Loop Rollers and Necessity of Repair

As a key component in production lines such as metallurgical rolling and printing, the failure of the loose loop roller is mostly due to the superimposed effect of complex working conditions:

1. Metallurgical industry: Cold-rolled live sleeves are subjected to dual impacts of mechanical cyclic loads and thermal cycles, making their surfaces prone to oxidation, cracking, wear, and even roll breakage.

2. Printing industry: The rollers are constantly subjected to compression, friction and ink corrosion, resulting in scratches and rust, which directly affects the precision of the printed products.

Laser cladding can specifically repair these defects, extending the service life by 30% to 100%, and the repair cost is only 1/3 to 1/2 of replacing with a new one.

Iii. Core technical Advantages of laser cladding Repair Processing for Live loop Rollers

1. Outstanding performance

The hardness of the cladding layer can reach HRC56-68(the highest hardness of the tungsten carbide reinforcing layer is HRC68), featuring excellent wear resistance, corrosion resistance and fatigue resistance, and capable of withstanding high temperatures and alternating loads. In a certain case, the surface finish of the repaired roller reached mirror level (Ra0.056), and its service life was directly doubled.

2. High precision and low damage

The heat-affected zone is only 0.1-0.2mm, with a dilution rate of 5%-10%, effectively preventing substrate deformation. The coating thickness is controllable (0.1-4mm), with dimensional accuracy within 0.01mm, and no extensive subsequent processing is required.

3. Efficient and environmentally friendly

The speed of the ultra-high-speed cladding line can reach 100m/min, with an efficiency 3 to 4 times that of traditional processes. Moreover, there is no electroplating pollution throughout the process, replacing the chromium plating process to achieve an environmental protection upgrade.

3. Wide adaptability

It supports various powders such as iron-based, nickel-based and ceramic, and can repair movable rollers made of cast iron, steel, stainless steel and other materials, taking into account both the strengthening of new and old roller parts and the repair of local damage.