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Product Description
In cement plants, mining operations, and power generation, components used for crushing and grinding are subjected to relentless abrasion. Materials like cement clinker, ore, and coal can destroy standard steel rolls in a short time, leading to frequent downtime, lost production, and high replacement costs.
Yile Machinery provides a superior, cost-effective solution: custom-engineered hardfaced rolls. By welding a highly durable alloy layer onto a tough steel core, we create a composite roll designed for maximum life in the most severe abrasive environments.
Instead of using a solid, expensive, and potentially brittle alloy casting, our hardfacing process delivers the ultimate combination of surface hardness and core toughness.
Ductile Base Roll: We begin with a robust and tough base roll, typically forged from materials like 42CrMo (AISI 4140) or 45# Steel. This core provides the structural strength to absorb shock loads and resist fracture.
Automated Welded Overlay: Using advanced processes like Submerged Arc Welding (SAW) or Open-Arc Welding (FCAW) , we apply multiple layers of a specialized hardfacing alloy to the roll's surface.
Creation of a Wear-Proof Surface: The welding wire is a high-chromium, high-carbon alloy. During welding, it forms an extremely hard deposit rich in chromium carbides. This metallurgical structure is exceptionally resistant to scratching and gouging abrasion.
Our hardfaced clinker rolls translate advanced manufacturing into tangible benefits for your operation.
Extreme Abrasion Resistance: The high-chromium carbide surface achieves a hardness of HRC 58-65, providing significantly longer service life than through-hardened or standard alloy steel rolls.
Excellent Impact Toughness: The softer, forged steel core prevents catastrophic cracking and failure from tramp metal or shock loading—a common problem with brittle cast high-chrome irons.
Cost-Effective & Repairable: This manufacturing method is often more economical than producing a solid exotic alloy roll. Furthermore, worn rolls can often be repaired and rebuilt by stripping the old layer and re-applying a new hardfacing overlay, dramatically reducing lifetime ownership costs.
Precision Finish: After the welding process, the rolls are precision machined and ground to ensure perfect concentricity, balance, and dimensional accuracy for smooth operation.
Our custom hardfaced rolls are the ideal solution for a range of high-wear applications:
Cement Production: Clinker Crusher Rolls, Grinding Table Segments
Mining & Mineral Processing: High-Pressure Grinding Rolls (HPGR), Crusher Rolls
Power Generation: Coal Pulverizer Rolls, Grinding Rolls
Steel Industry: Sinter Crusher Rolls
Tired of replacing your crusher rolls too often? Contact our engineering team. Provide your drawings or discuss your specific wear challenges, and we will design a hardfaced roll solution to extend your uptime and reduce your costs.
