Industry News

Roller press rollers are subjected to high pressure and high wear conditions for a long time in industries such as cement and mining. The surface is prone to wear and peeling, which affects the efficiency and service life of the equipment. Flux-cored wire surfacing technology uses a composite welding material with alloy powder wrapped in a metal sheath to form a wear-resistant/corrosion-resistant surfacing layer on the roller surface by arc melting, which can greatly improve the wear resistance of the roller surface and reduce maintenance costs.

Compared with other surfacing methods, flux-cored wire surfacing has unique advantages. First, the alloy composition is flexible. According to the actual working environment and wear resistance requirements of the roller press roller, the alloy elements in the flux core can be accurately adjusted to create a suitable surfacing layer. Second, the welding process has excellent performance, stable welding process, high deposition efficiency, and can quickly complete the surfacing operation and reduce equipment downtime.

Our company produces various types of flux-cored welding wires. The welding wires used for surfacing on roller presses are mainly the following:

• ZM is used for surfacing of the comprehensive transition layer in roller press repair, and has very good crack resistance.

• ZD1 is the first layer welding material, used for surfacing crack arrest transition layer, which can effectively prevent the extension and development of welding cracks and fatigue cracks on the roller surface to the roller body, and protect the roller body from damage.

• ZD2 is the second layer welding material, used for surfacing buffer isolation layer. It has very good bonding with ZD1 and ZM surfacing layers, and at the same time has a good supporting effect on ZD3 surfacing layer.

• ZD3 is the third layer welding material, suitable for surfacing of wear-resistant roller surface of roller press. The surfacing metal has high weld hardness and good crack resistance, and has excellent comprehensive performance against abrasive wear and extrusion wear.

• ZD310, ZD316, ZD330, ZD501, ZD600, ZD320 are used for wear-resistant pattern surfacing on the surface of roller press. It is a multi-element high alloy reinforcement, and the surfacing layer has better abrasive wear resistance and extrusion wear resistance than ZD3.

In actual operation, the flux-cored wire surfacing of roller press rollers needs to follow strict process specifications. First, the roller surface should be pre-treated to thoroughly remove impurities such as oil and rust to ensure that the surfacing layer and the roller core can be well combined. Secondly, according to the material, size and working conditions of the roller, carefully select the appropriate flux-cored wire and welding parameters, including welding current, voltage, welding speed, etc. In addition, the interlayer temperature must be strictly controlled during the surfacing process to prevent defects such as cracks and pores in the surfacing layer due to excessively high or low temperatures. Finally, after the surfacing is completed, the surfacing layer must be subjected to necessary post-heat treatment to eliminate residual stress and further improve the performance of the surfacing layer.

Flux-cored wire cladding technology provides an efficient and reliable solution for improving the wear resistance of roller press rollers. By properly using this technology, enterprises can effectively improve the operating stability and production efficiency of equipment, reduce production costs, and enhance their competitiveness in the market.