Submerged Arc Welding Cladding Equipment for Roll Press Squeeze Rolls

Literature Overview

This 2019 technical document originates from a collaboration between the National Engineering Laboratory for Advanced Metal Coatings at the Central Iron and Steel Research Institute and the Technology Center of Shanghai Meishan Steel Co., Ltd. The research focuses on the development and application of submerged arc welding (SAW) cladding equipment specifically designed for roll press squeeze rolls. The authors include Wang Y. J., Huang Q. X., Huang X., Jiang S. M., and Zhang Q. F., representing a cross-institutional effort combining fundamental research with industrial practice. The casting technology classification indicates that the work bridges traditional roll manufacturing with modern surface engineering approaches.

Core Technical Content

The application of SAW cladding on squeeze rolls addresses a critical industrial need: extending the service life of roll press components subjected to severe abrasive and adhesive wear conditions. Squeeze rolls in roll press operations experience extreme contact stresses, cyclic loading, and abrasive interactions with strip material. The base steel of the roll body is typically a low-carbon or medium-carbon steel selected for machinability and cost-effectiveness, while the cladding layer must provide superior wear resistance, hardness, and sometimes improved surface finish properties.

The SAW process was selected for this application due to several inherent advantages: high deposition rates compared to manual or semi-automatic processes, excellent penetration characteristics, and the ability to deposit thick layers in relatively few passes. The equipment design must account for the cylindrical geometry of the roll, requiring specialized fixtures, multi-axis positioning systems, and automated wire feed control.

Key Technical Parameters

Process Considerations

The equipment design must incorporate several critical subsystems. The roll mounting fixture must ensure concentricity within 0.1 mm TIR to prevent eccentricity during welding and subsequent grinding. The torch carriage system requires precise linear and rotational synchronization to maintain consistent weld bead placement on the cylindrical surface. Wire feeding must be stable with minimal spatter to ensure smooth surface profiles that minimize post-weld grinding requirements.

Flux handling is particularly important in this application. The equipment must provide adequate flux coverage over the weld zone while preventing flux contamination from the roll surface. A dedicated flux return and recycling system reduces material costs and ensures consistent flux properties throughout the cladding operation.

Engineering Practice and Quality Control

The quality of the cladding layer directly determines the service performance of the squeeze roll. Several quality control measures are essential:

• Ultrasonic testing (UT) for bond strength verification between base metal and cladding layer
• Dye penetrant testing (PT) for surface defects and cracks
• Hardness profiling across the cross-section to verify microstructure transitions
• Metallographic examination for inclusion and porosity assessment
• Wear testing using standardized methods (e.g., dry sand rub test)

Common defects encountered in this application include lack of fusion at the base-cladding interface, hot cracking in high-alloy overlay layers, and excessive dilution from the base metal. Countermeasures include proper preheating, controlled interpass temperatures, selection of appropriate filler metal composition, and optimized welding sequence to manage residual stress distribution.

The economic justification for SAW cladding on squeeze rolls is compelling. A typical roll press squeeze roll may cost several times more after cladding and machining than a plain steel roll, but the service life extension of 3 to 5 times provides a favorable cost-per-hour-of-operation ratio. The automated nature of the SAW process also reduces labor costs and improves consistency compared to manual overlay methods.

Study Insights and Implications

This work represents the practical maturation of SAW cladding technology in the steel rolling industry. The integration of equipment design with process optimization demonstrates a systems engineering approach that is essential for industrial-scale implementation. The collaboration between a national research laboratory and a major steel producer illustrates the pathway from laboratory development to production deployment.

One key insight is that equipment design must be process-driven rather than process-driven. The mechanical design of the cladding equipment must accommodate the metallurgical requirements of the cladding process, including thermal input management, flux protection quality, and geometric accuracy. Future improvements may include real-time monitoring of weld pool conditions, adaptive parameter control based on sensor feedback, and integration with digital twin concepts for predictive maintenance of the cladding equipment itself.

The reference value of this work lies in its demonstration that specialized cladding equipment, properly designed and operated, can significantly enhance the performance and economics of roll press operations. Engineers working in surface engineering and equipment manufacturing should study the design philosophy behind this equipment and apply similar principles to other cylindrical component cladding applications.