Four-roll lower roll.

The four-roll lower roll in current operation experiences rapid wear, resulting in a short service life of approximately 6 months. This limited durability leads to frequent refurbishments, increased maintenance costs, and production downtime. The accelerated wear reduces overall efficiency and reliability of the system, creating a need for a more robust solution that can extend the roll’s operational lifespan and minimize interruptions.

Objective: To extend the service life of the four-roll lower roll, which previously wore out within 6 months, by applying a layered welding alloy solution designed for both buffering and hardfacing. Solution Approach: Buffer Layer Application: - Material Used: Hardface 19.9.6-0 - Purpose: Acts as a buffer layer to absorb stress and provide a strong foundation for subsequent hardfacing. - Benefit: Improves bonding between the base material and the hardfacing alloy, reducing risk of cracking. Rebuild and Hardfacing: - Material Used: Hardface Mill 100 - Purpose: Applied to rebuild worn surfaces and provide superior wear resistance. - Benefit: Extends roll life by significantly reducing abrasion and surface degradation.