Development of Manufacturing Process for High-Chromium Steel Large Welding Roll

Abstract:

Due to the operating conditions of weld and calibrating rolls used in the production processes of large electric-welded pipes, their material is subject to stringent wear and abrasion resistance requirements at high temperatures. The limited capabilities of conventional Cr-Mn-Ni tool steels and open die forging technologies with heat treatment processes do not provide the required performance properties for large welded rolls. Therefore, the material of the product was replaced with Cr12MoV high-chromium steel. This required identifying the formation patterns of the fine grain structure of high-chromium steel in order to adjust the production technology with adaptation to the unique conditions and equipment (12.5 MN hydraulic forging press, heating and thermal furnaces) of the forging shop. The technology was offered, which included the development of modes from heating to heat treatment with intermediate two-stage forging from Cr12MoV steel ingots in two sets of combined dies. At the first stage, deformation with a low reduction ratio ε = 5% and a relative feed rate of 0.4 per pass was provided to break and refine the carbide mesh, and at the second stage, intense deformation with a reduction ratio ε = 15% was performed. Further practical application has shown that the durability of weld rolls made from the new material increases by 20–30%.

• Periodical: Defect and Diffusion Forum (Volume 430)
• Pages: 23-29
• DOI: https://doi.org/10.4028/p-S55ows
• Online since: January 2024
• Authors: Volodymyr V. Kukhar*, Oleg Vasylevskyi, Khrystyna Malii, Vadym Zurnadzhy, Bohdan Efremenko, Ivan Sili
• Keywords: Carbide Inhomogeneity, Cogging, Grain Size, Heat Treatment, Heating Schedule, Microstructure, Open Die Forging

References

[1] R.Y. Alsada, Y. Kumar, A measurement of quality costs in industrial organizations, Cogent Business & Management, 9(1) (2022) 2128253.

DOI: 10.1080/23311975.2022.2128253

[2] H. Saranga, R. George, J. Beine, U. Arnold, Resource configurations, product development capability, and competitive advantage: An empirical analysis of their evolution, Journal of Business Research, 85 (2018) 32-50.

DOI: 10.1016/j.jbusres.2017.11.045

[3] A.B. Solanki, S.S. Sonigra, V. Vajpayee, Implementation of quality tools and effective strategies to boost production market standards for forged crankshafts: A case study of forging industry, Materials Today: Proceedings, 47(17) (2021) 5970-5976.

DOI: 10.1016/j.matpr.2021.04.537

[4] W. Zhang, G. Zhao, Q. Fu, Study on the effects and mechanisms of induction heat treatment cycles on toughness of high frequency welded pipe welds, Materials Science and Engineering: A, 736 (2018) 276-287.

DOI: 10.1016/j.msea.2018.09.004

[5] C. Cheng, K. Kadoi, S. Tokita, H. Fujii, K. Ushioda, H. Inoue, Effects of carbon and chromium on microstructure evolution and mechanical properties of friction stir weldment in medium-carbon steel, Materials Science and Engineering: A, 762 (2019) 138060.

DOI: 10.1016/j.msea.2019.138060

[6] O. Kurpe, V. Kukhar, R. Puzyr, V. Burko, E. Balalayeva, E. Klimov, Electric motors power modes at synchronization of roughing rolling stands of hot strip mill, in: Proc. 25th IEEE International Conference on Problems of Automated Electric Drive. Theory and Practice, PAEP, Kremenchuk, Ukraine, IEEE, 2020, 1-4.

DOI: 10.1109/paep49887.2020.9240818

[7] V.I. Zurnadzhy, V.G. Efremenko, K. Wu, I. Petryshynets, K. Shimizu, A.M. Zusin, M.N. Brykov, V.A. Andilakhai, Tailoring strength/ductility combination in 2.5 wt% Si-alloyed middle carbon steel produced by the two-step Q-P treatment with a prolonged partitioning stage, Materials Science and Engineering: A, 791 (2020) 139721.

DOI: 10.1016/j.msea.2020.139721

[8] V.I. Zurnadzhy, V.G. Efremenko, I. Petryshynets, K. Shimizu, M.N. Brykov, I.V. Kushchenko, V.V. Kudin, Mechanical properties of carbide-free lower bainite in complex-alloyed constructional steel: Effect of bainitizing treatment parameters, Kovove Materialy, 58 (2020) 129-140.

DOI: 10.4149/km_2020_2_129

[9] S. G. Karnaukh, O. E. Markov, V. V. Kukhar, A. A. Shapoval, Classification of steels according to their sensitivity to fracture using a synergetic model, International Journal of Advanced Manufacturing Technology, 119(7-8) (2022) 5277-5287.

DOI: 10.1007/s00170-022-08653-y

[10] O.E. Markov, O.V. Gerasimenko, V.V. Kukhar, O.R. Abdulov, N.V. Ragulina, Computational and experimental modeling of new forging ingots with a directional solidification: The relative heights of 1.1, Journal of the Brazilian Society of Mechanical Sciences and Engineering, 41(8) (2019) 1-13.

DOI: 10.1007/s40430-019-1810-z

[11] O.E. Markov, I.S. Aliiev, L.I. Aliieva, N.S. Hrudkina, Computerized and physical modeling of upsetting operation by combined dies, Journal of Chemical Technology and Metallurgy, 55(3) (2020) 640-648.

[12] Y. Gao, Y. Liu, L. Wang, X. Yang, T. Zeng, L. Sun, R. Wang, Microstructure evolution and wear resistance of laser cladded 316L stainless steel reinforced with in-situ VC-Cr7C3, Surface and Coatings Technology, 435 (2022) 128264.

DOI: 10.1016/j.surfcoat.2022.128264

[13] L.X. Li, Y.H. Wang, W.J. Wang, J.Y. Liu, Z.Q. Xu, F.S. Du, Mechanism and prediction of hydrogen embrittlement based on complex phase structure of chromium alloy steel, Materials Science and Engineering: A, 822 (2021) 141546.

DOI: 10.1016/j.msea.2021.141546

[14] D. Music, U. Kreissig, R. Mertens, J.M. Schneider, Electronic structure and mechanical properties of Cr7C3, Physics Letters A, 326(5-6) (2004) 473-476.

DOI: 10.1016/j.physleta.2004.04.068

[15] Y. Ma, M. Guo, W. Li, Y. Yang, P. Gao, Y. Cui, W. Sun, Y. Wang, L. Wang, Y. Dong, Microstructure and properties of Cr7C3-CrSi2 composite coatings prepared by plasma spraying, Surface and Coatings Technology, 412 (2021) 127011.

DOI: 10.1016/j.surfcoat.2021.127011

[16] V.V. Kukhar, Producing of elongated forgings with sharpened end by rupture with local heating of the workpiece method, Metallurgical and Mining Industry, 6 (2015) 122-132.

[17] A. Rosa-Sainz, M.L. García-Romeu, I. Ferrer, M.B. Silva, G. Centeno, On the effective peek application for customized cranio-maxillofacial prostheses: An experimental formability analysis, Journal of Manufacturing Processes, 86 (2023) 66-84.

DOI: 10.1016/j.jmapro.2022.12.044

[18] V.V. Kukhar, O.V. Vasylevskyi, Experimental research of distribution of strains and stresses in work-piece at different modes of stretch-forging with rotation in combined dies, Metallurgical and Mining Industry, 3 (2014) 71-78.

[19] X. Liu, C. Zhu, S. Sun, R.i Ma, Rotary forging with multi-cone rolls, Journal of Manufacturing Processes, 56(A) (2020) 656-666.

DOI: 10.1016/j.jmapro.2020.05.037

[20] I. Zhbankov, L. Aliieva, K. Malii, Simulation of microstructure changes of steel during the open die forging process, Journal of Chemical Technology and Metallurgy, 55(3) (2020) 523-529.

[21] J.A. Suris, C.C. Yurgel, R. Alves de Sousa, Influence of the Grain-Flow Orientation after Hot Forging Process Evaluated through Rotational Flexing Fatigue Test, Metals, 13 (2023) 187.

DOI: 10.3390/met13020187

[22] A.A. Emamverdian, Y. Sun, C. Chunping, Deformation and wear in a H21 (3Cr2W8V) steel die during hot forging: Simulation, mechanical properties, and microstructural evolution, Journal of Materials Research and Technology, 15 (2021) 268-277.

DOI: 10.1016/j.jmrt.2021.08.022

[23] T.V. Olshanskaya, A.Y. Dushina, D.N. Trushnikov, Research of the technological methods influence on the formation of structure and properties during the additive growth of products from nickel chromium steels of the austenitic class by plasma-jet hard facing methods, Journal of Physics: Conference Series, 2275 (2022) 012003.

DOI: 10.1088/1742-6596/2275/1/012003

[24] A. Feng, J. Zhao, J. Lin, X. Pan, H. Feng, C. Wang, Z. Lu, Effect of Laser Quenching-Shock Peening Strengthening on the Microstructure and Mechanical Properties of Cr12MoV Steel, Materials, 15 (2022) 6693.

DOI: 10.3390/ma15196693

[25] L. Gong, Y. Pan, C. Peng, X. Fu, Z. Jiang, S. Jiang, Effect of ultrasonic surface rolling processing on wear properties of Cr12MoV steel, Materials Today Communications, 33 (2022) 104762.

DOI: 10.1016/j.mtcomm.2022.104762

[26] H. Wang, Y. Zhai, L. Zhou, Z. Zhang, B. Liu, Analysis of Austempering Characteristics of Cr12MoV Die Steel, Journal of Physics: Conference Series, 2338 (2022) 012019.

DOI: 10.1088/1742-6596/2338/1/012019

[27] Y. Gao, Y. Tong, L. Guohui, P. Lu, D. Zhang, Microstructure and Mechanical Properties of Ni-Based Alloy Composite Coating on Cr12MoV by Laser Cladding, Coatings, 12 (2022) 1632.

DOI: 10.3390/coatings12111632

[28] Y. Liu, Z. Li, G. Li, et al., Friction and wear behavior of Ni-based alloy coatings with different amount of WC–TiC ceramic particles, Journal of Materials Science, 58 (2023) 1116-1126.

DOI: 10.1007/s10853-022-08084-w

[29] A. Leonov, Y. Denisova, V. Denisov, M. Savchuk, V. Tishchenko, Tribotechnical and mechanical properties of CrN/TiN multi-layer coatings deposited on the surface of die steel, AIP Conference Proceedings, 2533 (2022) 020019.

DOI: 10.1063/5.0098843

[30] J.J. Sheng, Property and forging technology of steel Cr12MoV. Metalforming Machinery (China), 2 (1997) 40-42.

[31] V. Kukhar, O. Vasylevskyi, O. Khliestova, I. Berestovoi, E. Balalayeva, Hydraulic press open die forging of 21CrMoV5-7 steel CCM roller with flat upper and concave semi-round lower cogging die, Lecture Notes in Mechanical Engineering, In: Advanced Manufacturing Processes III. InterPartner 2021, Springer, Cham (2022) 489-498.

DOI: 10.1007/978-3-030-91327-4_48

[32] J. Jiang, Y. Liu, C. Liu, Effect of forging ratio on the microstructure, mechanical properties and abrasive wear behavior of a new C–Cr–Mo–V martensitic steel, Journal of Materials Research and Technology, 19 (2022) 4076-4091.

DOI: 10.1016/j.jmrt.2022.06.069