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In summary, cemented carbide composite rolls outperform traditional rolls in wear resistance, precision, and longevity, making them the optimal choice for modern high-performance rolling applications.
Time: 2025-04-18 Hit: 6
In the metal rolling industry, the choice of rolls directly impacts production efficiency, product quality, and processing costs. Cemented carbide composite rolls (WC-Co/Ni-based), cast iron rolls (such as chilled cast iron, ductile cast iron), and high-boron steel rolls are three common types. xingzhou Company will compare the core advantages of cemented carbide composite rolls in terms of wear resistance, service life, machining accuracy, and cost-effectiveness.
Key Performance Comparison Table
| Indicator | Cemented Carbide Composite Rolls | High-Boron Steel Rolls | Cast Iron Rolls |
|---|---|---|---|
| Hardness (HRA) | 85–93 | 60–75 | 50–65 |
| Wear Resistance | Excellent (5–10x longer than cast iron) | Moderate | Poor |
| Compressive Strength (MPa) | ≥3000 | 1500–2000 | 800–1200 |
| Heat Resistance (°C) | 800–1000 | 500–700 (prone to softening) | 400–600 (prone to thermal cracking) |
| Elastic Modulus (GPa) | 500–700 | 200–250 | 150–200 |
| Impact Resistance | Low (requires composite design) | High | Moderate |
| Applicable Rolling Speed | High speed (≥1000 m/min) | Medium speed (300–800 m/min) | Low speed (≤300 m/min) |
| Surface Finish (Ra) | ≤0.1 μm | 0.2–0.5 μm | 0.5–1.0 μm |
Core advantages of cemented carbide combination rollers
1. The high hardness of cemented carbide combination rollers leads to an ultra-long service life (up to 3 years or longer, more than 10 times that of cast iron rollers and high-boron steel rollers), reducing downtime and reducing the frequency of roller replacement.
2. The wear resistance of cemented carbide is 3 to 5 times that of high-boron steel. It is not easy to produce scratches or wear grooves on the roller surface during rolling. Cemented carbide rollers are especially suitable for high-precision strip steel (such as stainless steel and silicon steel). Ultra-thin foil (lithium battery copper foil thickness ≤ 6μm).
3. Cemented carbide can still maintain stability above 800℃, which is suitable for high-speed hot rolling (such as titanium alloy rolling) and high-temperature conditions of continuous rolling mills. Cast iron and high-boron steel are prone to thermal softening (hardness reduction) and thermal cracking (caused by uneven cooling) at high temperatures.
4. The elastic modulus of cemented carbide is more than 3 times that of cast iron, and the deformation during rolling is extremely small, which can control the strip thickness tolerance to be extremely small (±0.005mm) and the flatness of the plate shape (such as the wavy edge defect of 6σ copper foil is reduced by 50%).
5. Cemented carbide has strong corrosion resistance and adapts to complex environments: WC-Ni series is resistant to acid and alkali corrosion and is suitable for the copper foil rolling liquid environment. The surface can be chrome plated or DLC coated to further extend the life. High-boron steel and cast iron are prone to rust during wet rolling (such as pickling lines).
6. Lower overall cost: The initial price of cemented carbide rollers is 2~3 times that of high-boron steel, but considering the life and downtime losses. Cemented carbide rollers reduce the rolling cost of a ton of steel by 30%~50%. Reduce the labor and scrap rate of roller replacement (such as the scrap rate of copper foil rolling from 5% to less than 1%).
In short, carbide combination rollers completely outperform traditional rollers in terms of wear resistance, precision and life.
