Process for the manufacture of a roll and a roll

Abstract: The invention concerns a process for the manufacture of a roll, in particular of a calender roll for a paper machine. In the process the mantle (11) of the roll (10) is cast or cast and heat-treated and, in the next step, the roll mantle (11) is machined. In the process, the surface layer (15) of the cast-iron roll mantle (11) is hardened and tempered so that, in the surface layer (15) of the roll mantle (11), a temper-martensitic structure is produced. In a way in itself known, the roll mantle (11) is subjected to finishing machining. The invention also concerns a roll, in particular a calender roll for a paper machine, which roll is provided with a cast-iron mantle (11). The surface layer (15) of the roll mantle (11) is hardened and tempered so that the surface layer (15) of the roll mantle (11) is temper-martensitic.

Description: The invention concerns a process for the manufacture of a roll, in particular of a calender roll for a paper machine, in which process the mantle of the roll is cast or cast and heat-treated and, in the next step, the roll mantle is machined. Further, the invention concerns a roll, in particular a calender roll for a paper machine, said roll being provided with a cast-iron mantle. Traditionally, as the roll mantles of paper machine rolls, especially of calender rolls, chilled-iron roll mantles have been used, which are manufactured by casting grey cast iron or alloys of same into a chill mould, whereby, by the effect of the chill mould, the outer face of the cast piece is cooled rapidly and becomes graphite-free white iron. The structure of white iron consists of hard iron carbides and of perlite. The white irons are hard, highly wear-resistant, and hard to machine. A drawback of chilled-iron roll mantles is impact brittleness resulting from the material as well as sensitivity to sudden changes in temperature, for which reason it has been necessary to limit their use in applications in which the temperatures change. Moreover, owing to the process of manufacture, i.e. chill cast, the hard white layer becomes uneven, which results in a form error in the roll and in uneven distribution of temperature when the operating temperature rises. Owing to the carbides-containing microstructure of the surface layer, the wear of the roll face is uneven, which can be seen in the paper and which also causes re-grinding of the roll at intervals of about 6 months. Also, the service life of the chill moulds used for the casting is limited, and their cost of manufacture is high. Moreover, since several different kinds of chill moulds are needed, high sums of capital are bound in them. Moreover, owing to the high hardness of white iron, the machining of chilled-iron roll mantles is very difficult, and therefore the costs of manufacture of the rolls become high. As is well known, attempts have been made to replace mantles of chilled-iron rolls by roll mantles of steel, in which the temperature limitations of the chilled-iron rolls do not occur. Chilled-iron mantles cannot be used at high temperatures, of about 250°C, and, moreover, when such mantles are used, strict limits are imposed on the rate of cooling/heating, e.g. 0.5-2°C per minute, and the difference in temperature between the inner face and the outer face of the roll must never be higher than 30-50°C. Unless the above limitations are complied with, the thermal shock will cause damage to the chilled-iron rolls. When steel mantles are used, these limitations of temperature do not occur, but, for example, doctoring causes problems, because doctoring is considerably more precise, and the doctor is worn extensively when steel mantles are used. Moreover, the mantle of a steel roll is polished during operation, and the adhesion of paper to the roll is increased, with resulting problems in the threading of the web. Also, the ability of steel to attenuate oscillations is lower than that of cast irons. From the prior art, such solutions are also known for roll mantles in which the surface of a cast-iron roll mantle has been re-melted while thereby producing white iron in the surface layer, i.e. the objective has been to provide a process substituted for chill cast, whereby a microstructure similar to chilled-iron roll mantles is produced. One such process is described in the US Patent 4,452,647, wherein a process and a device are described for the manufacture of hard-faced cast-iron pieces, in particular of rolls, such as rolls for steel industry or paper calendering rolls, as well as a roll, cylinder or equivalent manufactured by means of the process. In this prior-art solution, it has been considered novel that the cast pieces, such as rolls and cylinders, are cast in sand or in an equivalent way so that, in connection with the solidification, substantially a crystal structure of grey cast iron is produced in them and that, after this stage, a re-melting treatment is carried out by making use of an electron jet or jets to produce a cast hard at the surface. Thus, in this prior-art solution, a treatment of re-melting of the surface has been employed, which has been carried out after the work piece had been machined close to the ultimate dimensions, the process of surface-treatment being an electron jet or jets so as to produce a heating effect that can be controlled and machined precisely. A second prior-art solution in which the surface is treated by means of the electron-jet melting process to produce a hardened cementite-carbide surface layer is described in the US Patent 4,000,011. Further, a prior-art solution based on re-melting of the surface is described in the DE Patent 3,640,131, which discloses a mantle that has a hard mantle face and a process for the manufacture of a roll with a hard mantle face in particular for paper machines, which roll is made of cast iron that has been cast in a sand mould and, after rapid cooling, on the roll, an outer carbides-containing layer is produced together with a grey core zone. In this prior-art solution, the cast roll is pre-heated to temperatures of 400-600°, and the pre-heated surface layer is heated rapidly beyond the liquidus temperature successively until the desired local melt layer is reached, and this melt layer is cooled rapidly to produce a carbides-containing zone, and finally the whole roll is cooled to the ambient temperature. DE-A-1 179 721 discloses the use of spheroidal cast iron for a calender roll which may comprise 3% Cr, Mg or Mo as a carbide former for obtaining a hardness of 480-620 HB after surface hardening. In all of the prior-art solutions described above, attempts have been made to provide a carbides-containing microstructure in the surface layer of the roll mantle, in which structure particles of iron carbides, i.e. cementite, are present. These iron carbides are very hard, and, when the roll is used, the roll face is worn around the carbides, and the carbides remain on the surface as outwards projecting peaks. The flaw produced by these peaks can also be noticed in the papers produced. In the prior-art solutions, in connection with the rolls that are heated, problems have also been caused by the variations in the shape of the roll mantle when the temperature changes. In particular when the structure of the roll mantle consists of two different materials, for example when the inner part is made of flake-graphite cast iron and when the mantle surface is made of white iron after chill cast, changes in temperature result in problems, because the properties of thermal expansion and thermal conductivity of these different layers are different and, moreover, the thickness of the layer varies. Especially the variations in shape and dimensions of the roll mantle are problematic, because the paper quality is deteriorated. The object of the invention is to provide a process for the manufacture of a roll in which the problems and drawbacks of the prior-art processes of manufacture do not occur and by whose means a roll is provided whose properties are better than those of prior-art rolls, in particular a roll that is suitable for use at higher temperatures without particular limitations of use. A further object of the invention is to provide a roll whose manufacture is easier and simpler and therefore also more economical for paper machine applications, in particular for calendering. In view of achieving the objectives stated above and those that will come out later, the process in accordance with the invention is defined in claim 1 and mainly characterized in that, in the process, the surface layer of the cast-iron roll mantle is hardened and tempered so that, in the surface layer of the roll mantle, a temper-martensitic structure is produced, and that, in a way in itself known, the roll mantle is subjected to finishing machining. Preferred embodiments of the method are defined in claims 2-4. Further, the roll in accordance with the invention is defined in claim 5 and mainly characterized in that the surface layer of the roll mantle is hardened and tempered so that the surface layer of the roll mantle is temper-martensitic. Preferred embodiments of the roll are defined in claims 6-7. According to a preferred embodiment of the invention, when a spheroidal graphite cast iron of higher strength and tenacity is used and when the face of the roll mantle is surface-hardened, e.g. by flame hardening or induction hardening, a temper-martensitic structure is achieved, which is harder than the prior-art chilled-iron roll mantle, whose wear resistance is better, and whose wear is more uniform because of the favourable microstructure, so that the interval of grinding of the roll is increased substantially. Owing to the basic material of higher tenacity and strength, the roll in accordance with the invention is not sensitive even to high changes in temperature, and deformations are not produced in the roll even at high operating temperatures, for, by means of the surface hardening, a highly uniform hardened layer is obtained on the roll mantle. Moreover, the work piece can be machined to its ultimate dimensions before hardening, so that the cost of machining of the roll is lowered significantly. A further advantage of the process in accordance with the invention is the possibility of re-hardening of the roll mantle after the hard layer has been ground off. The roll in accordance with the invention, which has a hard-faced roll mantle, which is cast out of a cast iron alloyed suitably in view of the hardening, and whose face has been hardened after machining, whereby a temper-martensitic microstructure is formed in the surface, is favourable in calendering of paper because of its fine particle structure. The intervals of grinding of the rolls in accordance with the invention become longer than with the prior-art rolls, because of higher hardness and better resistance to wear of the face as compared, e.g., with chilled-iron rolls. In a roll in accordance with the invention, high operating temperatures do not cause deformations, because, in principle, the roll mantle is made of one and the same material. The surface structure of the roll in accordance with the invention, i.e. the temper-martensitic microstructure, is worn uniformly, and no peak points distinguishable from the surface remain in it as a result of wear, whereby the quality of paper that is achieved is better. In respect of its strength value, rigidity, and tenacity, the spheroidal graphite cast iron, which is used in a roll in accordance with a preferred embodiment of the invention, is a material that has better properties than the properties of flake graphite cast iron, which is used, as a rule, in chill casting. An advantage of the roll in accordance with the invention, as compared with the prior-art solutions based on steel mantle, is the lubricating effect of the graphite present as mixed in the temper-martensite in the roll mantle, so that the wear of a doctor is not extensive, as it is in the case of steel mantles. The most important advantages of the roll in accordance with the invention, which has a mantle of cast iron, as compared with a chilled-iron mantle, are: fine and uniform microstructure uniform, hard surface layer homogeneous material and, consequently, smaller deformations and more uniform surface temperature at high temperatures, above 100°C not sensitive to changes in temperature better resistance to wear higher tensile strength higher impact ductility higher rigidity. In the following, the invention will be described in more detail with reference to the figures in the accompanying drawing, wherein Figure 1 is a schematic illustration of a roll, Figure 2 is a schematic sectional view taken along the line A-A in Fig. 1, Figure 3 shows the microstructure of the surface of the roll mantle of a prior-art chilled-iron roll as a 200-fold enlargement, Figure 4 shows a martensitic microstructure as a 500-fold enlargement, and Figure 5 shows a microstructure with graphite nodules on a martensite base as a 200-fold enlargement. The roll that is shown schematically in Fig. 1 is denoted with the reference numeral 10. The roll 10 comprises a roll mantle 11 and axle journals 13. The face of the roll mantle 11 is denoted with the reference numeral 12. The roll 10 shown in Fig. 1 is just a simple exemplifying embodiment. The roll mantle 11 in accordance with the invention is, of course, also suitable for use in much more complicated rolls. Fig. 2 is a sectional view taken along the line A-A in Fig. 1. The outer face 12 of the roll mantle 11 is hard because of the surface-hardened layer 15. The inner part of the roll mantle 11 is denoted with the reference numeral 16. In the process in accordance with the invention, first the roll mantle 11 is cast so that a fully perlitic or ferritic-perlitic microstructure is produced which is at least 60-percent perlitic. The material has been alloyed, e.g., so that C 3.0-3.8 %, Si 1.5-3.0 %, Mn 0.5-0.9 %, P less than 0.05 %, and S less than 0.02 %. As further alloying agents are used Cr, Ni, Cu, Mg, Mo, Sn, and/or Al. Hereupon the cast roll mantle blank 11 is subjected to machining. The machined roll mantle 11 is surface-hardened, and before the surface hardening, if necessary, pre-heating is carried out. The surface hardening is carried out preferably as induction hardening or flame hardening. Hereupon the roll mantle 11 is tempered in order that the surface should obtain a temper-martensitic structure. The inner part 16 of the roll mantle has a perlitic or ferritic-perlitic structure. The tempering temperature is chosen in accordance with the future operating temperature of the roll 10. Hereupon the necessary finishing-grinding is carried out. The roll mantle 11 can also be manufactured so that, after the casting, heat treatment is possibly carried out to produce a perlitic structure. Hereupon, stress-relieving annealing is carried out. After machining and surface hardening, preferably induction or flame hardening, the roll mantle 11 is complete except for finishing grinding. In the process of the invention, the surface hardening is carried out preferably as induction hardening or flame hardening. Both of them are thermal surface-hardening methods, i.e. methods based on a heat effect, wherein the surface is heated rapidly for a short time and often locally to a hardening temperature suitable for the austenitic range, after which it is quenched before the interior has had time to be transformed to austenite. In flame hardening, the face is heated by means of a gas flame, and the quenching takes place usually by means of a water jet that follows after the flame. In induction hardening, at the depth of effect of the electric induction field, which is produced by means of an induction coil, eddy currents are formed in the steel or cast iron, which currents heat the piece internally. After heating, quenching is carried out, e.g., by means of a water jet. Fig. 3 shows the microstructure of the surface of a prior-art chill-cast roll mantle as a 200-fold enlargement. In the figure, cementite is seen on a perlite base. Cementite is denoted with the reference S and perlite with the reference P. Cementite S, i.e. iron carbides Fe 3 C, is hard, and when the roll face is worn in operation in the areas of perlite P, the cementites S remain in the face as projections. The hardness of the surface layer of white iron on such a chill-cast roll mantle is about 550-630 HV. The variation in the thickness of the surface layer is 5-25 mm. Fig. 4 shows a temper-martensitic structure as a 500-fold enlargement, said structure consisting of lens-shaped or needle-shaped crystals. Fig. 4 also shows a graphite nodule. Fig. 5 shows a hardened face with graphite nodules on a martensite base, such a base being provided on the roll in accordance with the invention. Martensite is denoted with the reference M. In martensite M, no particle interfaces or equivalent are seen. The graphite nodules are denoted with the reference G. The scale of enlargement in Fig. 3 is 200-fold. In particular, the uniformity of the martensite structure should be noticed. The hardness of such a temper-martensitic structure is about 680-720 HV, and the thickness variation of the surface-hardened layer less than 0.5 mm. In the following table, the properties of a prior-art chilled-iron roll mantle and of the mantle of a surface-hardened roll in accordance with the invention, in this particular case of an induction-hardened spheroidal graphite cast iron roll, are compared. CHILLED IRON SURFACE/INTERIOR INDUCTION-HARDENED SPHEROIDAL GRAPHITE CAST IRON SURFACE HARDNESS (HV) 550-630 680-720 HARD LAYER (mm) 6-15 8-10 THICKNESS VARIATION IN HARD LAYER (mm) < 25 < 0.5 DENSITY (kg/dm 3 ) 7.7/7.1 7.3 THERMAL CONDUCTIVITY (W/m °C) 20-28/55-62 30 THERMAL EXPANSION COEFFICIENT (1/°C 10 -6 ) 8.4/10.5 10 COEFFICIENT OF ELASTICITY (kN/mm 2 ) 175/100 175 BREAKING STRENGTH (N/mm 2 ) 120-200/100-140 650 ELONGATION AT BREAK (%) 0 1 IMPACT DUCTILITY (J/cm 2 ) 2 7 The material of the mantle 11 of the roll in accordance with the invention is primarily of one and the same material, cast iron, for example spheroidal graphite cast iron. The surface layer 15 of the roll is temper-martensitic after the surface hardening, and the interior part 16 is at least 60-percent perlitic. The thickness of the surface layer 15 is 5-30 mm, preferably about 8-10 mm. The hardness of the surface layer 15 of the roll mantle 11 is 680-720 HV, and the hardness of the interior part 200-300 HB. The roll 10 in accordance with the invention is suitable for use at temperatures of 250°C without particular limitations of use. Above, the invention has been described with reference to some preferred embodiments of same only, the invention being, however, by no means supposed to be strictly confined to the details of said embodiments. Many variations and modifications are possible within the scope of the idea defined in the following claims.

Claims: Process for the manufacture of a roll, in particular a calender roll for a paper machine, in which process the mantle (11) of the roll (10) is cast or cast and heat-treated and, in the next step, the roll mantle (11) is machined, said process comprising the step of hardenin the surface layer (15) of the cast-iron roll mantle (11), wherein the roll mantle (11) is hardened and tempered so that, in the surface layer (15) of the roll mantle (11), a temper-martensitic structure i produced, and so that the thickness of the surface layer (15) is 5-30 mm that the microstructure of the roll mantle (11) is transformed into at least 60 percent perlitic spheroidal graphite cast iron in said casting stage or casting and heat-treatment stage and that, in a way in itself known, the roll mantle (11) is subjected to finishing machining. Process as claimed in claim 1, characterized in that, if necesary, the roll mantle (11) is pre-heated before hardening. Process as claimed in any of the claims 1 to 2, characterized in that the hardening is carried out as surface hardening. Process as claimed in any of the claims 1 to 3, characterized in that, the surface hardening is carried out as induction or flame hardening. Roll, in particular a calender roll for a paper machine, said roll (10) having a cast-iron mantle (11), wherein the surface layer (15) of the roll mantle (11) is hardened and tempered so that the surface laser (15) of the roll mantle (11) is temper-martensitic, and so that the thickness of the surface layer (15) is 5-30 mm the mantle (11) being made of spheroidal graphite cast iron and the interior portion (16) of the roll mantle (11) being perlitic at least to an extent of 60%, the mantle comprising 3,0-3,8% C, 1,5-3,0% Si, 0,5-0,9% Mn ≥ 0,05% P, and ≤ 0,02% S, and an additional alloying agent/agents in the mantle (11) made of spheroidal graphite cast iron being Cr, Ni, Cu, Mg, Mo, Sn, and/or Al. Roll mantle as claimed in claim 5, characterized in that the hardness of the surface layer (15) of the mantle (11) is 680-720 HV. Roll as claimed in claim 5 or 6, characterized in that the hardness of the interior part (16) of the mantle (11) is 200-300 HB.

Inventors: VAEHAEPESOLA JARI, VAEHAEPESOLA, JARI, Vähäpesola, Jari
Applicants: VALMET CORP, VALMET CORPORATION
Application year: 1992
Main classification: C21D5
IPC codes: C21D5, B21B27, C21D9, D21G1