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Do you know what factors determine the life of tungsten carbide corrugating rolls?

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Corrugating rolls is the "heart" parts of the corrugated cardboard production line, the wear resistance and service life of the corrugated cardboard production line are the main technical indicators to measure the quality and economy.
But do you know what factors affect the service life of corrugating rolls? Through my explanation, you will thoroughly understand the corrugating rolls.

The service life of the corrugating rolls is determined by the quality of the spraying. Our company uses Swiss Metco, a supersonic flame spraying system (HVOF), and tungsten powder is also imported material.
The principle of tungsten carbide coating is to heat tungsten carbide powder to 2000-3000 degrees, turn it into molten liquid, spray it onto the roller surface at supersonic speed, turn it into a tungsten layer flake, and hold it firmly on the roller surface. The hardness of tungsten carbide coating is HV1300 on average. The lowest point is not less than HV1200, and the hardness is second only to diamond. It can be said that it is almost never worn. Therefore, when the corrugating rolls reaches the end of its service life, it is not because the tungsten carbide is worn, but because the bonding force is no longer good and the local tungsten layer falls off. This causes pits on the roller surface and it can no longer be used.

So what are the factors that cause the wear of tungsten carbide coating on corrugating rolls?

1.Operating environment: For some customers with good operating environment, the pressure of corrugating rolls and pressure roller is only 2-3 kg all year round, so the impact of the three rollers is small, the tungsten carbide coating is less impacted, and the life is long. If the pressure is 5-6kg all year round, the impact on the tungsten carbide coating will be great, and the service life will be relatively much shorter.

2.The width of the produced cardboard: The corrugated cardboard of small size is produced all year round, and the corrugating rolls is severely impacted and worn in the middle, which can easily shorten the service life of the corrugating rolls.

3.The quality of the base paper: If the base paper used by the customer is good and has a high gram weight, it can pass smoothly between the corrugating rolls, the corrugating rolls will wear less, the buffer between the corrugating rolls is good, and it is not easy to wear. The base paper used by some customers is rough and has many impurities, especially the base paper with high sand content, which can easily damage the corrugating rolls body. For example, some sand particles are stuck between the corrugating rolls, which will press pits on the surface of the corrugating rolls, and the tungsten carbide coating will fall off.

4.Start-up stability: Some customers change orders frequently, often accelerate and decelerate, change paper, and the roller may be deformed due to factors such as speed, temperature, and steam, resulting in local impact and affecting the life. Some customers have many orders and run continuously at a constant speed, and the service life of the corrugating rolls will be significantly longer.