Patent Application
20210370371
The present invention relates to a composite cemented carbide roll used for rolling strips, plates, wires, rods, etc. of steel, which comprises an outer layer of cemented carbide metallurgically bonded to an inner layer made of a material having excellent toughness, and a method for producing a composite cemented carbide roll.
To meet the requests for higher quality such as improved dimensional accuracy, reduced surface defects, improved surface gloss, etc. of rolled steel, cemented carbide having excellent wear resistance, surface roughening resistance, etc. is used for rolls for rolling wires, rods, plates, etc. of steel. As is known, the cemented carbide is a sintered alloy of tungsten carbide (WC) bonded by a metal binder such as Co, Ni, Fe, etc., and some cemented carbide comprises carbides of Ti, Ta, Nb, etc. in addition to WC.
Because cemented carbide is expensive and difficult to be formed into large products, rolls having a structure in which metal shaft is inserted into a cemented carbide sleeve are disclosed. For example, JP S60-83708 A discloses a method for pressure-fixing a cemented carbide sleeve to a shaft comprising arranging a heat-expanded spacer having a thickness gradually increasing from the inner periphery to the outer periphery around the shaft, together with the cemented carbide sleeve and a disc spring, sandwiching them by fixing members, and cooling the spacer to apply a large lateral pressure to the disk spring, thereby pressing a side surface of the sleeve. However, such a fitting method uses large numbers of members such as a spacer, fixing members, etc. in a complicated assembling structure, needing high assembling accuracy. As a result, it impractically needs a large number of assembling steps and high cost.
To solve the above problems, the applicant discloses by JP 2003-342668 A a composite cemented carbide roll comprising an outer layer made of cemented carbide and an inner layer made of an iron-based alloy which is metallurgically bonded to the outer layer, the outer layer containing 0.05% or less by mass of oxygen, and the inner layer containing 0.06% or more by mass of Cr. Because the cemented carbide and the iron-based alloy have thermal expansion coefficients of about 6×10−6/° C. and 12×10−6/° C., respectively, different about 2 times, large tensile stress is generated in a bonding boundary between the outer layer and the inner layer when cooled after metallurgical bonding. When rolling is conducted in this state, stress by rolling is added to the tensile stress, resulting in a combined stress applied to the bonding boundary. If the combined stress exceeded the bonding strength of the boundary, it would likely break the roll. Accordingly, to reduce residual tensile stress by generating a bainite or martensite transformation in the inner layer metallurgically bonded to the outer layer, at least 0.06% or more by mass of Cr, an bainite-forming element, is added to the inner layer.
In Example 3 of JP 2003-342668 A, a solid inner layer 1 made of an iron-based alloy having a composition comprising 0.31% by mass of C, 0.24% by mass of Si, 0.39% by mass of Mn, 3.25% by mass of Ni, and 1.81% by mass of Cr is arranged in a center of a HIP can of 200 mm in inner diameter and 2000 mm in length, and a cemented carbide material for an outer layer comprising 80% by mass of WC and 20% by mass of Co, and a cemented carbide material for an intermediate layer comprising 50% by mass of C and 50% by mass of Co are charged into a space between an outer surface of the inner layer and an inner surface of the HIP can, to conduct hot isostatic pressing (HIP).
A composite cemented carbide roll used for rolling strips can be long though variable depending on strip's widths. Because the outer layer and the inner layer are bonded by HIP, a large HIP furnace should be used to accommodate the entire composite roll. For example, as large a composite cemented carbide roll as more than 200 mm in outer diameter and more than 2000 mm in entire length suffers the problem of a high running cost of a HIP furnace. Further, in the case of a large composite cemented carbide roll having an entire length of more than 4000 mm, there is no HIP furnace capable of containing the composite roll, failing to produce a composite cemented carbide roll practically.
Also, JP H5-171339 A discloses a WC—Co—Ni—Cr cemented carbide, in which WC+Cr is 95% or less by weight, Co+Ni is less than 10% by weight, and Cr/Co+Ni+Cr is 2-40% by weight. JP H5-171339 A describes that because cemented carbide having such a composition has higher wear resistance and toughness than those of conventional composition alloys, it can be used for hot-rolling rolls and guide rollers, largely contributing to the reduction of a roll cost, such as increase in the rolling amount per caliber, the reduction of grinding amount, the reduction of breakage, etc. However, the rolling roll of cemented carbide composed of WC particles and a Co—Ni—Cr binder phase fails to conduct sufficient cold rolling of steel strips. Intensive research has revealed that such insufficient cold rolling is caused by in sufficient reduction of a steel strip, because the cemented carbide having a Co—Ni—Cr binder phase has as low compressive yield strength as 300-500 MPa, suffering fine dents due to yield on the roll surface during the cold rolling of steel strips.
JP 2000-219931 A discloses a cemented carbide comprising 50-90% by mass of submicron WC and a binder phase having hardenability, the binder phase comprising 10-60% by mass of Co, less than 10% by mass of Ni, 0.2-0.8% by mass of C, and Cr and W and optionally Mo and/or V, in addition to Fe, the molar ratios XC, XCr, XW, XMo and XV of C, Cr, W, Mo and V in the binder phase meeting 2XC<XW+XCr+XMo+XV<2.5XC, and the Cr content (% by mass) meeting 0.03<Cr/[100−WC (% by mass)]<0.05. JP 2000-219931 A describes that this cemented carbide has high wear resistance by the binder phase having hardenability. However, because this cemented carbide contains 10-60% by mass of Co in the binder phase, it has low hardenability, failing to exhibit sufficient compressive yield strength. Further, as fine WC particles as submicron provide this cemented carbide with poor toughness and thus poor cracking resistance, so that it is not usable for outer layers of rolling rolls.
In view of the above circumstances, a long composite cemented carbide roll having sufficient compressive yield strength, thereby less suffering dents on the roll surface due to yield even when used in the cold rolling of metal strips, and capable of being produced at low cost, is desired.
Accordingly, an object of the present invention is to provide a composite cemented carbide roll having high wear resistance and mechanical strength, which suffers less dents on the roll surface even in the cold rolling of metal strips, by forming an outer layer by cemented carbide having sufficient compressive yield strength.
Another object of the present invention is to provide a low-cost, long, composite cemented carbide roll capable of being used for rolling strips, particularly to a long, composite cemented carbide roll having a roll diameter of more than 200 mm and an entire length of more than 2000 mm.
In view of the above objects, the inventors have solved the above problems by conducting intensive research on the compositions of outer and inner layers and the composition of an iron-based alloy for a shaft. The present invention has been completed based on such finding.
Thus, the first composite cemented carbide roll of the present invention comprises an inner layer made of an iron-based alloy, and an outer layer of cemented carbide metallurgically bonded to an outer peripheral surface of the inner layer;
the cemented carbide forming the outer layer comprising 55-90 parts by mass of WC particles and 10-45 parts by mass of an Fe-based binder phase, and a binder phase in the outer layer having a chemical composition comprising 0.5-10% by mass of Ni, 0.2-2.0% by mass of C, 0.5-5% by mass of Cr, and 0.1-5% by mass of W, the balance being Fe and inevitable impurities;
a shaft member being metallurgically bonded to at least one axial end of the inner layer, and a shaft end member being welded to the shaft member;
the inner layer being made of an iron-based alloy containing 2.0% or more in total by mass of at least one selected from the group consisting of Cr, Ni and Mo; and
the shaft member and the shaft end member being made of an iron-based alloy containing 1.5% or less in total by mass of at least one selected from the group consisting of Cr, Ni and Mo.
In the first composite cemented carbide roll of the present invention, the cemented carbide forming the outer layer preferably contains substantially no composite carbides having equivalent circle diameters of 5 μm or more.
In the first composite cemented carbide roll of the present invention, the WC particles contained in the cemented carbide forming the outer layer preferably have a median diameter D50 of 0.5-10 μm.
In the first composite cemented carbide roll of the present invention, the binder phase in the cemented carbide forming the outer layer preferably further comprises 0.2-2.0% by mass of Si, 0-5% by mass of Co, and 0-1% by mass of Mn.
In the first composite cemented carbide roll of the present invention, the total amount of bainite phases and/or martensite phases in the binder phase in the cemented carbide forming the outer layer is preferably 50% or more by area.
The second composite cemented carbide roll of the present invention comprises an inner layer made of an iron-based alloy, an intermediate layer of cemented carbide metallurgically bonded to an outer peripheral surface of the inner layer, and an outer layer of cemented carbide bonded to an outer peripheral surface of the intermediate layer;
the cemented carbide forming the outer layer comprising 55-90 parts by mass of WC particles and 10-45 parts by mass of an Fe-based binder phase, and a binder phase in the outer layer having a chemical composition comprising 0.5-10% by mass of Ni, 0.2-2.0% by mass of C, 0.5-5% by mass of Cr, and 0.1-5% by mass of W, the balance being Fe and inevitable impurities;
the cemented carbide forming the intermediate layer comprising 30-65 parts by mass of WC particles and 35-70 parts by mass of an Fe-based binder phase, and a binder phase in the outer layer having a chemical composition comprising 0.5-10% by mass of Ni, 0.2-2.0% by mass of C, 0.5-5% by mass of Cr, and 0.1-5% by mass of W, the balance being Fe and inevitable impurities;
a shaft member being metallurgically bonded to at least one axial end of the inner layer, and a shaft end member being welded to the shaft member;
the inner layer being made of an iron-based alloy containing 2.0% or more in total by mass of at least one selected from the group consisting of Cr, Ni and Mo; and
the shaft member and the shaft end member being made of an iron-based alloy containing 1.5% or less in total by mass of at least one selected from the group consisting of Cr, Ni and Mo.
In the second composite cemented carbide roll of the present invention, the cemented carbide forming the outer layer and/or the intermediate layer preferably contains substantially no composite carbides having equivalent circle diameters of 5 μm or more.
In the second composite cemented carbide roll of the present invention, the WC particles in the cemented carbide forming the outer layer and/or the intermediate layer preferably have a median diameter D50 of 0.5-10 μm.
In the second composite cemented carbide roll of the present invention, the binder phase in the cemented carbide forming the outer layer and/or the intermediate layer preferably further contains 0.2-2.0% by mass of Si, 0-5% by mass of Co, and 0-1% by mass of Mn.
In the second composite cemented carbide roll of the present invention, the total amount of bainite phases and/or martensite phases in the binder phase in the cemented carbide forming the outer layer and/or the intermediate layer is preferably 50% or more by area.
In the first and second composite cemented carbide rolls of the present invention, the inner layer is preferably made of an iron-based alloy comprising 0.2-0.45% by mass of C, 0.5-4.0% by mass of Cr, 1.4-4.0% by mass of Ni, and 0.10-1.0% by mass of Mo, the balance being Fe and inevitable impurities.
In the first and second composite cemented carbide rolls of the present invention, the shaft member and the shaft end member are preferably made of an iron-based alloy comprising 0.2-0.58% by mass of C, 0-1.2% by mass of Cr, and 0-0.3% by mass of Mo, the balance being Fe and inevitable impurities.
The first method of the present invention for producing the first composite cemented carbide roll comprising an inner layer made of an iron-based alloy, and an outer layer of cemented carbide metallurgically bonded to the inner layer comprises
arranging an outer layer material which is a powder, green body, calcined body or sintered body of cemented carbide, around the inner layer made of an iron-based alloy containing 2.0% or more in total by mass of at least one selected from the group consisting of Cr, Ni and Mo;
abutting a shaft member made of an iron-based alloy containing 1.5% or less in total by mass of at least one selected from the group consisting of Cr, Ni and Mo, on at least one axial end of the inner layer;
sealing the outer layer material, the inner layer and the shaft member in a HIP can made of a steel material, and evacuating the HIP can; and
conducting a HIP treatment to integrally bond the outer layer material, the inner layer, and the shaft member.
In the first production method of the present invention, the cemented carbide forming the outer layer preferably comprises 55-90 parts by mass of WC particles, and 10-45 parts by mass of an Fe-based binder phase; and the binder phase in the outer layer preferably has a chemical composition comprising 0.5-10% by mass of Ni, 0.2-2.0% by mass of C, 0.5-5% by mass of Cr, and 0.1-5% by mass of W, the balance being Fe and inevitable impurities.
The second method of the present invention for producing the second composite cemented carbide roll comprising an inner layer made of an iron-based alloy, an intermediate layer made of cemented carbide, and an outer layer made of cemented carbide, which are metallurgically bonded to each other, comprises
arranging an intermediate layer material which is a powder, green body, calcined body or sintered body of cemented carbide, and an outer layer material which is a powder, green body, calcined body or sintered body of cemented carbide, around the inner layer made of an iron-based alloy containing 2.0% or more in total by mass of at least one selected from the group consisting of Cr, Ni and Mo;
abutting a shaft member made of an iron-based alloy containing 1.5% or less in total by mass of at least one selected from the group consisting of Cr, Ni and Mo on at least one axial end of the inner layer;
sealing the outer layer material, the intermediate layer material, the inner layer and the shaft member in a HIP can made of a steel material, and evacuating the HIP can; and
conducting a HIP treatment to integrally bond the outer layer material, the intermediate layer material, the inner layer, and the shaft member.
It is preferable that in the second production method of the present invention,
the cemented carbide forming the outer layer comprises 55-90 parts by mass of WC particles and 10-45 parts by mass of an Fe-based binder phase, the binder phase in the outer layer having a chemical composition comprising 0.5-10% by mass of Ni, 0.2-2.0% by mass of C, 0.5-5% by mass of Cr, and 0.1-5% by mass of W, the balance being Fe and inevitable impurities; and
the cemented carbide forming the intermediate layer comprises 30-65 parts by mass of WC particles and 35-70 parts by mass of an Fe-based binder phase, the binder phase in the intermediate layer having a chemical composition comprising 0.5-10% by mass of Ni, 0.2-2.0% by mass of C, 0.5-5% by mass of Cr, and 0.1-5% by mass of W, the balance being Fe and inevitable impurities.
In the first and second methods of the present invention for producing the composite cemented carbide roll, after the HIP treatment, a shaft end member made of an iron-based alloy containing 1.5% or less in total by mass of at least one selected from the group consisting of Cr, Ni and Mo is preferably welded to the shaft member.
The composite cemented carbide roll of the present invention can conduct the high-quality, continuous cold rolling of steel strips, and a long roll having a diameter of more than 2000 mm and an entire length of 2000 mm or more can be obtained at low cost.
In the production of a composite cemented carbide roll, a material for an inner layer should be selected to reduce residual stress in a boundary between the outer layer made of cemented carbide and the inner layer made of an iron-based alloy, but such inner layer actually suffers excessive residual stress due to large difference in thermal shrinkage from that of the cemented carbide of the outer layer having a small thermal expansion coefficient, failing to withstand actual rolling because of insufficient strength, or likely being broken during production. To avoid these problems, it is effective to cancel the thermal shrinkage of the inner layer by the transformation expansion of martensite, etc. during cooling after HIP bonding. To this end, 2% or more in total of alloy such as Cr, Ni and Mo contributing to improvement in hardenability should be added to the inner layer. On the other hand, because high-alloy steel for such inner layer is not resistant to cracking by welding, it is not easy to weld a shaft end member to the inner layer after HIP to obtain a necessary length, when the inner layer cannot achieve the necessary length due to the limitation of the HIP capacity. According to the present invention, which selects a shaft member made of an iron-based alloy containing small amounts of Cr, Ni and Mo which is suitable for welding by HIP, and abuts the shaft member on an end of the inner layer, and integrally bonds them by HIP, the roll is less likely broken when used for rolling, and a shaft portion can be elongated by welding to obtain a long composite cemented carbide roll at low cost.
The embodiments of the present invention will be explained in detail below. Explanations of one embodiment may be applicable to other embodiments unless otherwise mentioned. The following explanations are not restrictive, but various modifications may be made within the scope of the present invention.
[1] Composite Cemented Carbide Roll
The first composite cemented carbide roll of the present invention comprises an inner layer made of an iron-based alloy, and an outer layer made of cemented carbide, which is metallurgically bonded to an outer peripheral surface of the inner layer;
the cemented carbide comprising 55-90 parts by mass of WC particles and 10-45 parts by mass of an Fe-based binder phase, and a binder phase in the outer layer having a chemical composition comprising 0.5-10% by mass of Ni, 0.2-2.0% by mass of C, 0.5-5% by mass of Cr, and 0.1-5% by mass of W, the balance being Fe and inevitable impurities;
a shaft member being metallurgically bonded to at least one axial end of the inner layer, and a shaft end member being welded to the shaft member;
the inner layer being made of an iron-based alloy containing 2.0% or more in total by mass of at least one selected from the group consisting of Cr, Ni and Mo; and
the shaft member and the shaft end member being made of an iron-based alloy containing 1.5% or less in total by mass of at least one selected from the group consisting of Cr, Ni and Mo.
The second composite cemented carbide roll of the present invention comprises an inner layer made of an iron-based alloy, an intermediate layer made of cemented carbide which is metallurgically bonded to an outer peripheral surface of the inner layer, and an outer layer made of cemented carbide which is bonded to an outer peripheral surface of the intermediate layer;
the cemented carbide forming the outer layer comprising 55-90 parts by mass of WC particles and 10-45 parts by mass of an Fe-based binder phase, a binder phase in the outer layer having a chemical composition comprising 0.5-10% by mass of Ni, 0.2-2.0% by mass of C, 0.5-5% by mass of Cr, and 0.1-5% by mass of W, the balance being Fe and inevitable impurities;
the cemented carbide forming the intermediate layer comprising 30-65 parts by mass of WC particles and 35-70 parts by mass of an Fe-based binder phase, a binder phase in the outer layer having a chemical composition comprising 0.5-10% by mass of Ni, 0.2-2.0% by mass of C, 0.5-5% by mass of Cr, and 0.1-5% by mass of W, the balance being Fe and inevitable impurities;
a shaft member being metallurgically bonded to at least one axial end of the inner layer, and a shaft end member being welded to the shaft member;
the inner layer being made of an iron-based alloy containing 2.0% or more in total by mass of at least one selected from the group consisting of Cr, Ni and Mo; and
the shaft member and the shaft end member being made of an iron-based alloy containing 1.5% or less in total by mass of at least one selected from the group consisting of Cr, Ni and Mo.
[1-1] Cemented Carbide Forming Outer and Intermediate Layers
The cemented carbide forming the outer layer in the first composite cemented carbide roll, and the cemented carbide forming the outer and intermediate layers in the second composite cemented carbide roll will be explained below. It should be noted that the outer layers in the first and second composite cemented carbide rolls have the same composition unless otherwise mentioned.
(A) Composition
The cemented carbide forming the outer layer in the first and second composite cemented carbide rolls comprises 55-90 parts by mass of WC particles and 10-45 parts by mass of an Fe-based binder phase, and the cemented carbide forming the intermediate layer in the second composite cemented carbide roll comprises 30-65 parts by mass of WC particles and 35-70 parts by mass of an Fe-based binder phase.
The amount c1 of WC particles in the cemented carbide forming the outer layer is 55-90 parts by mass. When WC particles are less than 55 parts by mass in the outer layer, the amount of hard WC particles is relatively small, providing the cemented carbide with too low Young's modulus. On the other hand, when WC particles are more than 90 parts by mass, the amount of the binder phase is relatively small, failing to provide the cemented carbide with enough strength. The lower limit of the amount of WC particles in the outer layer is preferably 60 parts by mass, and more preferably 65 parts by mass. Also, the upper limit of the amount of WC particles in the outer layer is preferably 85 parts by mass.
To improve both the bonding strength of a boundary between the outer layer and the intermediate layer and the bonding strength of a boundary between the inner layer and the intermediate layer, while reducing circumferential and axial residual stress in or near the bonding boundaries, the amount c2 of WC particles in the cemented carbide forming the intermediate layer is 30-65 parts by mass. The lower limit of the amount of WC particles in the intermediate layer is preferably 33 parts by mass, and more preferably 35 parts by mass. Also, the upper limit of the amount of WC particles in the intermediate layer is preferably 60 parts by mass, and more preferably 55 parts by mass.
Further, the amounts of WC particles in the outer and intermediate layers are set, such that the amount c1 (parts by mass) of WC particles in the outer layer and the amount c2 (parts by mass) of WC particles in the intermediate layer meet the formula of 0.45≤c2/c1≤0.85. In the second composite cemented carbide roll of the present invention, in which the outer layer, the intermediate layer and the inner layer are metallurgically and integrally bonded by HIP as described below, by setting the amounts of WC particles in the outer and intermediate layers as described above, the thermal shrinkage of the intermediate layer can be made intermediate between those of the outer and inner layers, thereby reducing residual stress in a cooling process after HIP. The lower limit of c2/c1 is preferably 0.5, and more preferably 0.55. Also, the upper limit of c2/c1 is preferably 0.8, and more preferably 0.75.
(1) WC Particles
WC particles contained in the cemented carbides forming the outer layer and the intermediate layer preferably have a median diameter D50 (corresponding to a particle size at a cumulative volume of 50%) of 0.5-10 μm. When the average particle size is less than 0.5 μm, there are increased boundaries between the WC particles and the binder phase, making it likely to generate composite carbides described below, thereby reducing the strength of the cemented carbide. On the other hand, when the average particle size exceeds 10 μm, the strength of the cemented carbide is lowered. The lower limit of the median diameter D50 of WC particles is preferably 1 μm, more preferably 2 μm, and most preferably 3 μm. Also, the upper limit of the median diameter D50 of WC particles is preferably 9 μm, more preferably 8 μm, and most preferably 7 μm.
Because WC particles densely exist in a connected manner in the cemented carbide, it is difficult to determine the particle sizes of WC particles on the photomicrograph. Because the cemented carbide used in the present invention is produced by sintering a green body at a temperature between (liquid phase generation-starting temperature) and (liquid phase generation-starting temperature+100° C.) in vacuum as described below, there is substantially no particle size difference between WC powder in the green body and WC particles in the cemented carbide. Accordingly, the particle sizes of WC particles dispersed in the cemented carbide are expressed by the particle sizes of WC powder in the green body.
WC particles preferably have relatively uniform particle sizes. Accordingly, in a cumulative particle size distribution curve determined by a laser diffraction and scattering method, the WC particles have a preferable particle size distribution defined below. The lower limit of D10 (particle size at a cumulative volume of 10%) is preferably 0.3 μm, and more preferably 1 μm, and the upper limit of D10 is preferably 3 μm. Also, the lower limit of D90 (particle size at a cumulative volume of 90%) is preferably 3 μm, and more preferably 6 μm, and the upper limit of D90 is preferably 12 μm, and more preferably 8 μm. The median diameter D50 is as described above.
WC particles contained in the outer layer and the intermediate layer may be the same or different as long as they meet the above particle size distribution, though the use of the same WC particles is preferable.
(2) Binder Phase
In the cemented carbide forming the outer layer and the intermediate layer, the binder phase has a composition comprising
0.5-10% by mass of Ni,
0.2-2% by mass of C,
0.5-5% by mass of Cr, and
0.1-5% by mass of W,
the balance being Fe and inevitable impurities.
(i) Indispensable Elements
(a) Ni: 0.5-10% by mass
Ni is an element necessary for securing the hardenability of the binder phase. When Ni is less than 0.5% by mass, the binder phase has insufficient hardenability, likely lowering the material strength. On the other hand, when Ni exceeds 10% by mass, the binder phase is turned to have an austenite phase, resulting in cemented carbide having no sufficient compressive yield strength. The lower limit of the Ni content is preferably 2.0% by mass, more preferably 2.5% by mass, further preferably 3% by mass, and most preferably 4% by mass. Also, the upper limit of the Ni content is preferably 8% by mass, and more preferably 7% by mass.
(b) C: 0.2-2.0% by mass
C is an element necessary for securing the hardenability of the binder phase and suppressing the generation of composite carbides. When C is less than 0.2% by mass, the binder phase has insufficient hardenability, and large amounts of composite carbides are generated, resulting in low material strength. On the other hand, when C exceeds 2.0% by mass, coarse composite carbides are generated, providing the cemented carbide with low strength. The lower limit of the C content is preferably 0.3% by mass, and more preferably 0.5% by mass, and the upper limit of the C content is preferably 1.5% by mass, and more preferably 1.0% by mass.
(c) Cr: 0.5-5% by mass
Cr is an element necessary for securing the hardenability of the binder phase. When Cr is less than 0.5% by mass, the binder phase has too low hardenability, failing to obtain sufficient compressive yield strength. On the other hand, when Cr exceeds 5% by mass, coarse composite carbides are generated, providing the cemented carbide with low strength. Cr is preferably 4% or less by mass, and more preferably 3% or less by mass.
(d) W: 0.1-5% by mass
The W content in the binder phase is 0.1-5% by mass. When the W content in the binder phase exceeds 5% by mass, coarse composite carbides are generated, providing the cemented carbide with low strength. The lower limit of the W content is preferably 0.8% by mass, and more preferably 1.2% by mass. Also, the upper limit of the W content is preferably 4% by mass.
(ii) Optional Elements
(a) Si: 0.2-2.0% by mass
Si, which is an element strengthening the binder phase, may be contained if necessary. Less than 0.2% by mass of Si has substantially no effect of strengthening the binder phase. On the other hand, when Si is more than 2.0% by mass, graphite is likely crystallized, providing the cemented carbide with low strength. Accordingly, Si is preferably 0.2% or more and 2.0% or less by mass, if contained. A further effect of strengthening the binder phase is exhibited when the Si content is 0.3% or more by mass, particularly when it is 0.5% or more by mass. Also, the upper limit of the Si content is preferably 1.9% by mass.
(b) Co: 0-5% by mass
Co, which has a function of improving sinterability, is not indispensable in the cemented carbide used in the present invention. Namely, the Co content is preferably substantially 0% by mass. However, 5% or less by mass of Co does not affect the structure and strength of the cemented carbide. The upper limit of the Co content is more preferably 2% by mass, and most preferably 1% by mass.
(c) Mn: 0-5% by mass
Mn, which has a function of improving hardenability, is not indispensable in the cemented carbide used in the present invention. Namely, the Mn content is preferably substantially 0% by mass. However, 5% or less by mass of Mn does not affect the structure and strength of the cemented carbide. The upper limit of the Mn content is more preferably 2% by mass, and most preferably 1% by mass.
(iii) Inevitable Impurities
The inevitable impurities include Mo, V, Nb, Ti, Al, Cu, N, O, etc. Among them, at least one selected from the group consisting of Mo, V and Nb is preferably 2% or less by mass in total. At least one selected from the group consisting of Mo, V and Nb is more preferably 1% or less by mass, and most preferably 0.5% or less by mass, in total. Also, at least one selected from the group consisting of Ti, Al, Cu, N and O is preferably 0.5% or less by mass alone and 1% or less by mass in total. Particularly, each of N and O is preferably less than 1000 ppm. The inevitable impurities within the above ranges do not substantially affect the structure and strength of the cemented carbide.
Though the binder phases in the cemented carbides forming the outer layer and the intermediate layer may have the same or different compositions, they preferably have the same composition.
(B) Structure
(1) Composite Carbides
The cemented carbides forming the outer layer and the intermediate layer preferably contain substantially no composite carbides having equivalent circle diameters of 5 μm or more. The composite carbides are those of W and metal elements, for example, (W, Fe, Cr)23C6, (W, Fe, Cr)3C, (W, Fe, Cr)2C, (W, Fe, Cr)7C3, (W, Fe, Cr)6C, etc. Herein, the equivalent circle diameter of a composite carbide is a diameter of a circle having the same area as that of the composite carbide particle in a photomicrograph (about 1000 times) of a polished cross section of the cemented carbide. The cemented carbide containing no composite carbides having equivalent circle diameters of 5 μm or more in the binder phase has bending strength of 1700 MPa or more. Herein, “containing substantially no composite carbides” means that composite carbides having equivalent circle diameters of 5 μm or more are not observed on a SEM photograph (1000 times). Composite carbides having equivalent circle diameters of less than 5 μm may exist in an amount of less than about 5% by area when measured by EPMA, in the cemented carbides forming the outer layer and the intermediate layer of the composite cemented carbide roll of the present invention.
(2) Bainite Phases and/or Martensite Phases
The binder phases in the cemented carbides forming the outer layer and the intermediate layer preferably have a structure containing 50% or more in total by area of bainite phases and/or martensite phases. The use of the term “bainite phases and/or martensite phases” is due to the fact that bainite phases and martensite phases have substantially the same function, and that it is difficult to distinguish them on a photomicrograph. With such structure, the cemented carbides forming the outer layer and the intermediate layer in the composite cemented carbide roll of the present invention have high compressive yield strength and mechanical strength.
Because the total amount of bainite phases and/or martensite phases in the binder phase is 50% or more by area, the cemented carbide has compressive yield strength of 1200 MPa or more. The total amount of bainite phases and/or martensite phases is preferably 70% or more by area, more preferably 80% or more by area, and most preferably substantially 100% by area. Other structures than bainite phases and martensite phases are pearlite phases, austenite phases, etc.
(3) Diffusion of Fe into WC Particles
EPMA analysis has revealed that in the cemented carbides forming the outer layer and the intermediate layer in the composite cemented carbide roll of the present invention, WC particles contain 0.3-0.7% by mass of Fe.
The generation of dents on the roll surface can be suppressed in the outer layer of the cemented carbide roll of the present invention when used for the cold rolling of metal strips.
(C) Properties
The cemented carbide having the above composition and structure has compressive yield strength of 1200 MPa or more and bending strength of 1700 MPa or more. Accordingly, when a rolling roll having an outer layer (and an intermediate layer) made of such cemented carbide is used for the cold rolling of metal (steel) strips, dents due to the compressive yield of the roll surface can be reduced, enabling the continuous high-quality rolling of metal strips with a long life span of the rolling roll. Of course, the composite cemented carbide roll of the present invention can also be used for the hot rolling of metal strips.
The compressive yield strength is yield stress determined by a uniaxial compression test of a test piece shown in
The cemented carbides forming the outer layer and the intermediate layer have compressive yield strength of more preferably 1500 MPa or more, and most preferably 1600 MPa or more, and bending strength of more preferably 2000 MPa or more, and most preferably 2300 MPa or more.
The cemented carbides forming the outer layer and the intermediate layer further have Young's modulus of 385 GPa or more and Rockwell hardness of 80 HRA or more. The Young's modulus is preferably 400 GPa or more, and more preferably 450 GPa or more. Also, the Rockwell hardness is preferably 82 HRA or more.
[1-2] Inner Layer
The inner layer is made of an iron-based alloy having excellent toughness, which contains 2.0% or more in total by mass of at least one selected from the group consisting of Cr, Ni and Mo. Using such an iron-based alloy for the inner layer, bainite or martensite transformation can occur in the inner layer in a cooling process after the metallurgical bonding of the outer layer, the intermediate layer and the inner layer, thereby reducing the thermal expansion difference between the inner layer and the low-thermal expansion cemented carbide to reduce residual stress in the outer and intermediate layers.
The iron-based alloy for the inner layer preferably comprises 0.2-0.45% by mass of C, 0.5-4.0% by mass of Cr, 1.4-4.0% by mass of Ni, and 0.10-1.0% by mass of Mo, the balance being Fe and inevitable impurities.
(a) C: 0.2-0.45% by mass
C is an indispensable element alloyed with Fe to obtain good mechanical properties. When C is less than 0.2% by mass, the iron-based alloy has a high melting point, likely suffering defects. For relatively inexpensive production, C should be 0.2% or more by mass. When C exceeds 0.45% by mass, the iron-based alloy becomes harder, resulting in low toughness.
(b) Cr: 0.5-4.0% by mass
Cr is an element necessary for increasing the strength and hardenability of the material by alloying, making bainite or martensite transformation easier. When Cr is less than 0.5% by mass, sufficient strength cannot be obtained. Though Cr is effective for increasing hardenability and reducing residual stress, its amount may be 4% or less by mass. Because the addition of more Cr is disadvantageous in cost, the upper limit of Cr is 4% by mass.
(c) Ni: 1.6-4.0% by mass
Ni is an element effective for improving hardenability and making bainite or martensite transformation easier, and mainly reducing residual stress. Less than 1.6% by mass of Ni provides insufficient effect, while more than 4.0% by mass of Ni stabilizes austenite too much, making the transformation difficult.
(d) Mo: 0.1-1.0% by mass
Mo increases the strength and hardenability of the material, and is effective for making bainite or martensite transformation easier. When Mo added together with Cr and Ni for the above purpose is less than 0.1% by mass, its effect is insufficient. On the other hand, when Mo exceeds 1.0% by mass, the material becomes brittle.
Specific examples of the iron-based alloy used for the inner layer include nickel chromium molybdenum steels such as SNCM439, SNCM630, etc.
[1-3] Shaft Member and Shaft End Member
An iron-based alloy containing 1.5% or less in total by mass of at least one selected from the group consisting of Cr, Ni and Mo is used for the shaft member and the shaft end member. The shaft member and the shaft end member should have sufficient strength and wear resistance, because they are used as shafts bonded to the inner layer of the composite cemented carbide roll. Further, because the shaft end member is welded to the shaft member, the shaft member should be made of a material having good weldability to the shaft end member. Using the iron-based alloy containing 1.5% or less in total by mass of at least one selected from the group consisting of Cr, Ni and Mo, the shaft end member can be easily welded to an end of the shaft member after the HIP treatment, to obtain a long composite cemented carbide roll.
The iron-based alloy used for the shaft member and the shaft end member preferably comprises 0.2-0.58% by mass of C, 0-1.2% by mass of Cr, and 0-0.3% by mass of Mo, the balance being Fe and inevitable impurities. Though the shaft member and the shaft end member may have the same or different compositions, they preferably have the same composition from the aspect of weldability.
(a) C: 0.2-0.58% by mass
C is necessary for obtaining enough yield strength and hardness for the shaft member and the shaft end member. When C is less than 0.2% by mass, it is difficult to obtain sufficient strength and hardness. When C exceeds 0.58% by mass, cracking likely occurs in welding, making welding difficult.
(b) Cr: 0-1.2% by mass
Cr is effective for obtaining enough strength for the shaft member and the shaft end member. More than 1.2% by mass of Cr provides excessive hardenability, so that cracking likely occurs in welding.
(c) Mo: 0-0.3% by mass
Mo is effective for obtaining enough strength for the shaft member and the shaft end member. More than 0.3% by mass of Mo provides excessive hardenability, so that cracking likely occurs in welding.
Specific examples of the iron-based alloy used for the shaft member and the shaft end member include structural carbon steels such as S45C, S55C, etc., and chromium molybdenum steels such as SCM440, etc.
The bonding strength of a boundary between the inner layer and the shaft member is preferably 600 MPa or more in tensile strength.
[2] Production Method of Cemented Carbide
(1) Method of Using Sintered Body of Cemented Carbide
The production method of cemented carbide will be explained first in a case where a sintered body of cemented carbide is used for the outer layer (and the intermediate layer).
(A-1) Powder for Molding (Outer Layer)
55-90 parts by mass of WC powder, and 10-45 parts by mass of a metal powder comprising 2.5-10% by mass of Ni, 0.3-1.7% by mass of C, 0.5-5% by mass of Cr, 0.2-2.0% by mass of Si, 0-5% by mass of Co, and 0-2% by mass of Mn, the balance being Fe and inevitable impurities, are wet-mixed in a ball mill, etc., and dried to prepare a powder for molding of the cemented carbide. Because W is diffused from the WC powder to the binder phase during sintering, the metal powder may not contain W. The WC powder content is preferably 60-90 parts by mass, and more preferably 65-90 parts by mass. The upper limit of the WC powder content is preferably 85 parts by mass. To prevent the generation of composite carbides, C in the metal powder should be 0.3-1.7% by mass, and is preferably 0.5-1.5% by mass.
(A-2) Powder for Molding (Intermediate Layer)
30-65 parts by mass of WC powder, and 35-70 parts by mass of a metal powder comprising 2.5-10% by mass of Ni, 0.3-1.7% by mass of C, 0.5-5% by mass of Cr, 0.2-2.0% by mass of Si, 0-5% by mass of Co, and 0-2% by mass of Mn, the balance being Fe and inevitable impurities, are wet-mixed in a ball mill, etc., and dried to prepare the powder for molding of the cemented carbide. Because W is diffused from WC powder to the binder phase during sintering, the metal powder may not contain W. The WC powder content is preferably 33-65 parts by mass, and more preferably 35-65 parts by mass. The upper limit of the WC powder content is preferably 60 parts by mass. To prevent the generation of composite carbides, C in the metal powder should be 0.3-1.7% by mass, and is preferably 0.5-1.5% by mass.
The metal powder for forming the binder phases in the outer and intermediate layers may be a mixture of constituent element powders, or alloy powder containing all constituent elements. Carbon may be added in the form of powder such as graphite, carbon black, etc., or may be added to powder of each metal or alloy. Cr may be added in the form of an alloy with Si, for example, CrSi2. Each metal or alloy powder, for example, Fe powder, Ni powder, Co powder, Mn powder and CrSi2 powder, preferably has a median diameter D50 of 1-10 μm.
(B) Molding
In the production of the first composite cemented carbide roll, the powder for molding the outer layer is molded by a method such as die-pressing, cold-isostatic pressing (CIP), etc., to obtain a sleeve-shaped green body for the outer layer, which is bonded to an outer peripheral surface of the inner layer. Also, in the second composite cemented carbide roll, the powders for molding the outer and intermediate layers are molded by a method such as die-pressing, cold-isostatic pressing (CIP), etc., to obtain sleeve-shaped green bodies for the intermediate and outer layers, the outer layer being bonded to an outer peripheral surface of the inner layer via the intermediate layer.
(C) Sintering
The sleeve-shaped green bodies for the intermediate and outer layers are sintered at a temperature from (liquid phase generation-starting temperature) to (liquid phase generation-starting temperature+100° C.) in vacuum. The liquid phase generation-starting temperature of the green body is a temperature at which the generation of a liquid phase starts in the heating process of sintering, which is measured by a differential thermal analyzer.
(D) HIP Treatment
The sintered bodies are further subjected to a HIP treatment. Specific explanations will be made below in a case where the second composite cemented carbide roll is produced. Incidentally, the production of the first composite cemented carbide roll is the same as that of the second composite cemented carbide roll, except for using no sintered body for the intermediate layer.
For the HIP treatment, as shown in
(E) Cooling
After the HIP treatment, cooling is conducted at an average rate of 60° C./hour or more between 900° C. and 600° C. When cooled at an average rate of less than 60° C./hour, the binder phase in the cemented carbide contains a large percentage of pearlite phases, failing to have 50% or more in total by area of bainite phases and/or martensite phases, thereby providing the cemented carbide with low compressive yield strength. Cooling at an average rate of 60° C./hour or more may be conducted in the cooling process of HIP in a HIP furnace, or after cooling in the HIP furnace and then heating to 900° C. or higher again in another furnace.
(2) Method of Using Green or Calcined Body of Cemented Carbide
Though the above explanations are made on a case where the sleeve-shaped sintered body 12 for the intermediate layer and the sleeve-shaped sintered body 13 for the outer layer are used, sleeve-shaped green bodies of cemented carbide for the intermediate and outer layers, or sleeve-shaped calcined bodies of cemented carbide for the intermediate and outer layers may be used, in place of the sleeve-shaped sintered body 12 for the intermediate layer and the sleeve-shaped sintered body 13 for the outer layer. In a case where the green or calcined bodies are used, too, the composite cemented carbide roll is produced by sealing of the HIP can, the HIP treatment and then cooling, as in a case where the sintered bodies are used.
(3) Method of Using Cemented Carbide Powder
In the present invention, cemented carbide powder may be used for the outer layer (and the intermediate layer). When the cemented carbide powder is used, a HIP can is arranged around an outer peripheral surface of the inner layer 11 with a space therebetween, and a cylindrical partition sheet is placed in the space. the cemented carbide powder for the intermediate layer is charged into a gap between an outer peripheral surface of the inner layer and the partition sheet, and the cemented carbide powder for the outer layer is charged into a gap between the partition sheet and an inner surface of the HIP can. Thereafter, the partition sheet is removed, and the HIP can is sealed with an end surface of the shaft member 14 abutted on the end surface 11a of the inner layer. Like in the case of using the sintered body, the HIP treatment and the cooling are then conducted to produce a composite cemented carbide roll. When the intermediate layer is not formed, the cemented carbide powder for the outer layer may be charged into an only space for the outer layer provided around the inner layer 11.
Thus obtained is, as shown in
To achieve a desired product length, a shaft end member is welded to the end of the shaft member. Because the shaft end member is made of an easily weldable low-alloy material, various welding methods such as arc welding, friction welding, etc. can be conducted. After welding, a stress relief heat treatment may be conducted if necessary.
The present invention is effectively conducted by a step of bonding shaft end member 5 to the shaft member 4 by welding grooves 6 provided in both end portions of the shaft member 4 and the shaft end member 5 as shown in
[3] Uses
Because the composite cemented carbide roll of the present invention has an outer layer having high compressive yield strength, bending strength, Young's modulus and hardness, it is particularly suitable for the cold rolling of metal (steel) strips. The composite cemented carbide roll of the present invention is preferably used as a work roll in (a) a 6-roll stand comprising a pair of upper and lower work rolls for rolling a metal strip, a pair of upper and lower intermediate rolls for supporting the work rolls, and a pair of upper and lower backup rolls for supporting the intermediate rolls, or (b) a 4-roll stand comprising a pair of upper and lower work rolls for rolling a metal strip, and a pair of upper and lower backup rolls for supporting the work rolls. At least one stand described above is preferably arranged in a tandem mill comprising pluralities of stands.
The present invention will be explained in further detail by Examples below, without intention of restricting the present invention thereto.
WC powder [purity: 99.9%, and median diameter D50: 6.4 μm, D10: 4.3 μm, D50: 6.4 μm, and D90: 9.0 μm, which were measured by a laser diffraction particle size distribution meter (SALD-2200 available from Shimadzu Corporation)], and a binder phase powder having the composition shown in Table 1 were mixed at ratios shown in Table 2, to prepare powders for molding (Samples 1-10). Each binder phase powder had a median diameter D50 of 1-10 μm, and contained trace amounts of inevitable impurities.
Each of the powders for molding was wet-mixed for 20 hours in a ball mill, dried, and then pressed at pressure of 98 MPa to form a cylindrical green body (Samples 1-10) of 60 mm in diameter and 40 mm in height. The liquid phase generation-starting temperature of a test piece of 1 mm×1 mm×2 mm cut out of each green body was measured by a differential thermal analyzer. The results are shown in Table 3.
(1)The balance includes inevitable impurities.
Each green body was sintered in vacuum under the conditions shown in Table 4, and then subjected to HIP under the conditions shown in Table 4 to produce the cemented carbides of Samples 1-10. Each cemented carbide was evaluated by the following methods. Incidentally, Samples 7, 8 and 10 are outside the composition of the cemented carbide used in the composite cemented carbide roll of the present invention.
(1)An average cooling rate between 900° C. and 600° C.
(1) Compressive Yield Strength
Each compression test piece shown in
The results are shown in Table 5.
(2) Bending Strength
A test piece of 4 mm×3 mm×40 mm cut out of each cemented carbide was measured with respect to bending strength under 4-point bending conditions with an interfulcrum distance of 30 mm. The results are shown in Table 5.
(3) Young's Modulus
The Young's modulus of a test piece of 10 mm in width, 60 mm in length and 1.5 mm in thickness, which was cut out of each cemented carbide, was measured by a free-resonance intrinsic vibration method (JIS Z2280). The results are shown in Table 5.
(4) Hardness
The Rockwell hardness (A scale) of each cemented carbide was measured. The results are shown in Table 5.
(5) Observation of Structure
Each sample was mirror-polished, and observed by SEM to determine the presence or absence of composite carbides, and the total area ratio of bainite phases and martensite phases in the binder phase. The results are shown in Table 6.
(1) The total area ratio (%) of bainite phases and martensite phases in the binder phase.
(2) The presence or absence of composite carbides having diameters of 5 μm or more in the binder phase.
(6) Composition of Binder Phase
The composition of the binder phase in each sample was measured by a field emission electron probe microanalyzer (FE-EPMA). Point analysis was conducted with a beam diameter of 1 μm at 10 arbitrary points in portions other than WC particles, and the measured values were averaged to determine the composition of the binder phase. When there were composite carbides having diameters of 5 μm or more, other portions than WC particles and composite carbides were measured. The results are shown in Table 7.
(1)Analyzed values.
(2)The balance includes inevitable impurities.
Using a powder for molding having the same composition as that of Sample 1 in Reference Example 1, solid cylindrical green bodies were formed by the same method as in Reference Example 1. Each green body was sintered in the same manner as in Reference Example 1 to form an integral roll of 44 mm in outer diameter and 620 mm in length. Using this roll, a pure-Ni strip as thick as 0.6 mm was cold-rolled without suffering defects due to dents on the roll surface.
Using a powder for molding having the same composition as that of Sample 10 in Reference Example 1, an integral roll of 44 mm in outer diameter and 620 mm in length was similarly formed. Using this roll, a pure-Ni strip as thick as 0.6 mm was rolled without suffering defects due to dents on the roll surface.
Using the same material as that of Sample 1 in Reference Example 1, powder for molding having the composition shown in Table 8 was prepared, and formed into sleeve-shaped green bodies for outer and intermediate layers in the same manner as in Sample 1 in Reference Example 1. Like Sample 1 in Reference Example 1, the green bodies were sintered in vacuum, to produce a sleeve-shaped sintered body (outer diameter:194 mm, inner diameter: 171 mm, and length: 1050 mm) for the outer layer, and a sleeve-shaped sintered body (outer diameter:171 mm, inner diameter: 152 mm, and length: 1050 mm) for the intermediate layer.
(1)A ratio (% by mass) per the total amount of WC powder and the binder phase powder.
(2)The percentage of each metal in the binder phase powder.
(3)The balance includes inevitable impurities.
As shown in
With the HIP can placed in a HIP furnace, HIP was conducted at 1230° C. and 140 MPa. The HIPed outer and intermediate layers were cooled at an average rate of 80-100° C./hour.
Thus obtained was, as shown in
(1)Analyzed values.
(2)The balance includes inevitable impurities.
In the outer layer 3 of this composite cemented carbide roll 10, the measurement of its compressive yield strength, bending strength, Young's modulus and hardness, and the observation of its structure were conducted in the same manner as in Reference Example 1. The results are shown in Tables 10 and 11.
(1) The total area ratio (%) of bainite phases and martensite phases in the binder phase.
(2) The presence or absence of composite carbides having diameters of 5 μm or more in the binder phase.
As shown in
A sleeve-shaped sintered body (outer diameter: 298 mm, inner diameter: 264 mm, and length: 1720 mm) for an outer layer and a sleeve-shaped sintered body (outer diameter: 264 mm, inner diameter: 254 mm, and length: 1720 mm) for an intermediate layer were produced in the same manner as in Example 1, except for preparing powder for molding having the composition shown in Table 12.
(1)A ratio per the total amount of WC powder and the binder phase powder.
(2) The percentage of each metal in the binder phase powder.
(3)The balance includes inevitable impurities.
As shown in
With the HIP can placed in a HIP furnace, a HIP treatment was conducted at 1230° C. and 140 MPa. After the HIP treatment, the outer layer and the intermediate layer were cooled at an average rate of 80-100° C./hour.
Thus obtained was, as shown in
(1)Analyzed values.
(2)The balance includes inevitable impurities.
As shown in
| Number | Date | Country | Kind |
|---|---|---|---|
| 2018-015990 | Jan 2018 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2019/003404 | 1/31/2019 | WO | 00 |
