Mechanism analysis on dry-friction abrasive wear resistance of particulate reinforced MMC coatings by laser deposition for corrugated rollers

Abstract

Corrugated rolls (CR) are key components for production line of corrugated paper in packaging industry. Corrugated rolls suffer severe dry friction abrasive wear of the paper during production. Hardfacing of coatings with good abrasive wear resistance on CR by laser deposition is a promising technique to extend the lifetime of the CR. Previous research indicates that crack-free coatings with particulate reinforcement can be deposited on corrugated rolls with optimized composition and processing parameters. The laser deposited particulate reinforced MMC (PR-MMC) coating shows a hypoeutectic structure consisted of proeutectic austenite dendrites and eutectic matrix, in addition to a large amount of composite carbides precipitated in-situ during solidification and homogeneously distributing in the metal matrix. However, the mechanism on abrasive wear resistance in severe dry-friction wear conditions in corrugated paper production needs to be investigated.Three PR-MMC coatings with different hardness and size/proportion of particles were especially designed for analysis on microstructure and wear resistance. Results of wear tests indicate that the proportion and size of particles are main factors which influence the abrasive wear resistance besides the obdurability of matrix and strength of carbide particles. In real condition of CR, particles with the size of 1∼2 μm, are difficult to be pulled out or broken up, playing an important part on wear resistance. Distribution density (proportion) is another key factor. Lower free path between particles can prevent the abrasives from cutting the matrix.THW-65 coatings, optimized in size (1∼2 μm) and proportion (4.7×104/mm2), exhibits the best abrasive wear resistance in working condition of CR.Corrugated rolls (CR) are key components for production line of corrugated paper in packaging industry. Corrugated rolls suffer severe dry friction abrasive wear of the paper during production. Hardfacing of coatings with good abrasive wear resistance on CR by laser deposition is a promising technique to extend the lifetime of the CR. Previous research indicates that crack-free coatings with particulate reinforcement can be deposited on corrugated rolls with optimized composition and processing parameters. The laser deposited particulate reinforced MMC (PR-MMC) coating shows a hypoeutectic structure consisted of proeutectic austenite dendrites and eutectic matrix, in addition to a large amount of composite carbides precipitated in-situ during solidification and homogeneously distributing in the metal matrix. However, the mechanism on abrasive wear resistance in severe dry-friction wear conditions in corrugated paper production needs to be investigated.Three PR-MMC coatings with different hardness and size...