[Case Study] Regenerating Wear through Thermal Spraying to Contribute to Cost Reduction and Stable Operations
Rejuvenate wear with thermal spraying and contribute to cost reduction and stable operations!
At the paper processing factory, when the shafts of the rolls became worn and unusable, they were replaced with new ones, which was a source of concern due to the costs involved. Issues: 1. There are many rolls in use (including rubber rolls), and they want to reduce the manufacturing costs of the rolls as much as possible. 2. They want to extend the lifespan of the rolls and reduce the hassle and time involved in replacements. 3. It is difficult to predict shaft wear, and if there are no spare parts available, it can disrupt production.
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We propose the reuse and longevity of rolls through wear-resistant material thermal spraying. Points: 1. By using thermal spraying (with a coating thickness of up to 5mm), we can reduce costs by reusing rolls after use. 2. We select thermal spray materials and application methods that emphasize wear resistance, sliding properties, and adhesion to shafts to enhance longevity. The material used is chromium alloy (SUS420J2), applied using frame thermal spraying. (There are many types of thermal spray materials and application methods available, which can be selected according to the intended use and purpose.) 3. For this application on rubber rolls, we use a wire arc frame thermal spraying method that minimizes impact on the rubber (with shaft temperatures kept below 150°C). (If there is sufficient lead time, we will perform thermal spraying during the rubber rewrapping process.) 4. If urgent, we can complete the work within three days. (The lead time for new rubber rolls is over one month.) *This time, we delivered the work over two holiday days due to an urgent request.
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In today's world, where advanced technological capabilities are required of all Japanese companies, we aim to be a trading company that not only embodies "integrity" and "technology," but also explores our customers' needs and responds to their requests, rather than being just a simple trading company.