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HARD FACING: WORKING STEEL

ROLLS

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Whether you are talking about calendaring rolls, spreading rolls, leveling rolls drawing rolls or
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high temp rolls, working Steel Rolls are ubiquitous in the manufacturing process. Many
ABOUT US INDUSTRIES AND SERVICES RESOURCES AND QUALITY BLOG CONTACT US (860) 413-309
products that we come across every day were manufactured using working steel rolls of
some type. Some industry examples include paper manufacturing, textiles, and steel goods. Hard Facing: Working Steel Rolls
All these industries use working steel rolls to shape, form, strengthen and convey materials Read Customer Spotlight: Meet the Laser Cladding “It
through the manufacturing process. In many cases the surface of the rolls degrades and can Guys”
cause costly line down time or poor-quality manufactured materials. For this reason, many
Bespoke Laser Cladding Nozzles Made Possible w/
steel rolls are considered a very expensive consumable in the manufacturing process. We Powder Bed Fusion
see a variety of rolls issues including but not limited to a change in roll diameter and surface
Laser Cladding – Powerful Wear and Corrosion
quality. Solutions for Power

Hardfacing Internal Diameters with The Help of 3D

In many cases the lowest hanging fruit for reducing production costs associated with line
Printing
downtime is the fast and efficient refurbishment of the steel rolls. There are three common
methods used to repair working rolls which are plasma spray, HVOF and laser cladding.

Plasma Spraying – a process in which the material to be deposited (typically a powder, liquid, ARCHIVES

or wire) is introduced into a plasma jet emanating from a plasma torch. The material is melted
to the order of 10,000 K and propelled towards a substrate. The molten material then rapidly
 February 2021
solidifies leaving a deposit adhering to the substrate.
 June 2020

High Velocity Oxygen Fuel Spraying (HVOF) – a mixture of gaseous or liquid fuel and oxygen  May 2020
is fed into a combustion chamber where they are ignited and combusted continuously. The 
 April 2020
hot gases created by the process are at a pressure close to 1 MPa and emanated through a  March 2020

converging-diverging nozzle and travels through a straight section. The velocity at which the
ABOUT US INDUSTRIES AND SERVICES RESOURCES AND QUALITY BLOG CONTACT US (860) 413-309
gasses exit the barrel can exceed the speed of sound. A powder feed stock is then injected
into the gas stream which accelerates the powder up to 800 m/s. The stream of hot gas and CATEGORIES

powder is directed towards a substrate where the powder then melts and is deposited onto
the substrate resulting in a low porosity coating.
 3d printing

Laser Cladding (Laser Metal Deposition) – a method by which an engineered metal powder  Additive Manufacturing

or wire feedstock is melted and consolidated using a laser to coat a substrate or fabricate a  Laser Cladding
near-net shape part. The interaction of the engineered powder, laser and substrate produces
 Oil and Gas
a melt pool. The laser is then moved across the substrate leaving a track of solid metal. This
 Power Generation
creates a metallurgical bond versus an applied coating.
 Weld Overlay
Laser cladding could be the key to dramatically reducing downtime in these industries. By
using lasers and engineered metal powders to resurface (also known as hard facing or hard
surfacing) the diameter of the steel rolls, we can restore the diameters of the steel rolls to a
like new or even better than new condition. Typically, the surface of a laser clad roll is harder
and more resistant to corrosion and wear than a new unclad roll. This is due to the
metallurgical bond that is created vs. a traditional coating. A metallurgical bond is the result of
chemical bonding that occurs between a substrate and the engineered powder or wire
feedstock. Using laser cladding we can obtain the best balance between the two materials
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being bonded together and can be adjusted to enhance properties such as:
· Hardness

· Toughness ABOUT US INDUSTRIES AND SERVICES RESOURCES AND QUALITY BLOG CONTACT US (860) 413-309

· Strength

· Performance in extreme temperatures

· Fatigue

· Corrosion resistance

· Weight

If your production facility uses working steel rolls and is looking to dramatically increase the
useful life of the rolls (up to 10x), in turn reducing downtime, then you should be looking into
hard facing with laser cladding technology. If you are ever in doubt of which process to use,
just ask a trusted metallurgist whether a laser clad metallurgical bond is superior to a sprayed
or applied coating. You will likely find that laser cladding will be the top choice to outperform
the others by providing stronger, longer lasting equipment

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 ABOUT US INDUSTRIES AND SERVICES RESOURCES AND QUALITY BLOG CONTACT US (860) 413-309

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laser cladding – also known as laser
metal deposition or Directed Energy
Deposition (DED) – to protect, restore,
and strengthen the surfaces of metal
components. Our solutions improve wear
resistance, protect from corrosion and
erosion, and return parts to as-new
condition.

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