TNA is all set to provide Critical HVOF Tungsten carbide coating on Cold Rolling Mill Deflector rolls in the desired range of 500-800 micron with surface finish between Ra 2-4
44 CRM Sink ( Zn and Al Bath) Rolls -repair by Laser Cladding
TNA is working in close association with steel plant to improve the service life of various spares of ZN -Galvanizing line from current operating level to next level by providing systematic step by step life enhancement by improving each factors .
What is Laser Cladding?
Laser cladding is a fusion process that involves the deposition of a metallurgically bonded coating onto a substrate using a high-powered laser. This technique provides a robust solution for repairing and enhancing the surface properties of various machine parts, including sink rolls with lowest possible dilution with base metal of Rolls
Key Benefits of Laser Cladding
- Enhanced Wear Resistance: Laser cladding significantly improves the wear resistance of sink rolls, allowing them to withstand the abrasive nature of cement processing.
- Corrosion Resistance: The coatings applied through laser cladding provide an effective barrier against corrosion, extending the operational life of the rolls.
- Minimal Heat-Affected Zone: The low heat input associated with laser cladding minimizes the risk of distortion and heat-affected zone cracking, which can occur with traditional welding methods.
- Metallurgical Bonding: The process creates a strong metallurgical bond between the coating and the substrate, resulting in superior adhesion and performance compared to conventional coatings.
- Cost-Effectiveness: By extending the life of sink rolls and reducing the frequency of replacements, laser cladding offers a cost-effective maintenance solution for cement plants.
The Laser Cladding Process at TNA
Tarek Nasser Al Akeel Co. employs a systematic approach to laser cladding for sink rolls:
- Surface Preparation: The sink rolls are cleaned and pre-machined to remove any contaminants and to ensure a proper bond. This may involve degreasing or abrasive blasting.
- Laser Cladding Application: Using a precisely controlled laser beam, a high-performance alloy powder is deposited onto the surface of the roll. The laser melts the powder, creating a dense and strong coating that adheres to the substrate.
- Cooling and Stress Relief: After the cladding process, the rolls are stress-relieved to reduce any residual stresses that may have developed during the application.
- Final Machining: The coated rolls are then machined to restore their original dimensions and surface finish, ensuring they meet the required specifications for performance.
- Milling Operations: Enhancing the performance and longevity of rolls used in grinding processes.
- Quality Control: Maintaining consistent product quality by ensuring the geometric integrity of the rolls.
Conclusion
Laser cladding for CRM sink rolls is a vital maintenance practice that enhances the durability and performance of these critical components in cement plants. Tarek Nasser Al Akeel Co. provides specialized laser cladding services that not only extend the service life of sink rolls but also improve operational efficiency and reduce maintenance costs. By investing in laser cladding technology, cement manufacturers can achieve significant operational benefits, ensuring their machinery operates at peak performance. For more information on TNA’s laser cladding services, please contact us today.
