Prediction of service life of friction damage of WC coating on hot roll descaling rolls based on modified Archchard theory

Abstract

The friction damage data of hot rolling descaling rollers is limited by small sample size and challenges in data collection, significantly impacting the evaluation of the surface cladding coating’s service performance and life. To effectively assess the impact of Ni-based WC45 coating on the friction damage and service life of descaling rollers, a prediction method based on a modified Archard theory was proposed. By integrating experiments with finite element simulations, the friction characteristics and service life of the Ni-based WC45 coating were investigated. The results indicate that the primary mode of friction damage in the Ni-based WC45 coating is abrasive wear. While increasing operating temperatures exacerbate friction damage, they simultaneously reduce the friction coefficient. WC particles within the coating are deposited between the surface and transition layers, contributing to its superior wear resistance. The wear depth profile of the coating follows a “low-high-low” pattern and asymptotically approaches zero. The accuracy of the wear depth prediction model for the Ni-based WC45 coating, developed using the modified Archard theory, exceeds 90%. Compared to other forms of service damage, friction damage has a negligible effect on service life, and the Ni-based WC45 coating demonstrates excellent friction damage protection. These findings provide a theoretical foundation for optimizing the performance of the Ni-based WC45 coating for descaling rollers and offer a reliable basis for the precise maintenance of hot rolling descaling rollers.