In industrial production, roller crushers are important equipment widely used in the fields of ore crushing and building materials production. However, long-term use and harsh working environment make roller crusher spare parts prone to wear, cracks and other problems, affecting the normal operation and production efficiency of the equipment. Laser cladding technology, as an advanced surface repair technology, provides an efficient and reliable solution for the repair of roller crusher spare parts.

1. Common forms of damage to roller crusher spare parts

(I) Wear
During the process of crushing materials, the roller skin, tooth plate and other spare parts of the roller crusher are in direct contact with the materials, and are subject to friction and impact from the materials, and the surface is prone to wear. Wear will cause the spare parts to reduce in size and change in shape, reducing the crushing efficiency and product quality.

(II) Cracks
Due to long-term exposure to alternating loads and impact loads, the spare parts of the roller crusher are prone to fatigue cracks. In addition, when working in harsh environments such as high temperature and high humidity, spare parts may also crack due to factors such as thermal stress and corrosion. The expansion of cracks will cause spare parts to break, making the equipment unable to operate normally.

(III) Peeling
When the wear and cracks on the surface of the spare parts reach a certain level, local peeling will occur. Peeling will further aggravate the damage to the spare parts and shorten their service life.

2. The principle of laser cladding technology to repair roller crusher spare parts

Laser cladding technology uses a high-energy-density laser beam as a heat source to melt the preset or synchronously fed cladding material to form a metallurgically bonded cladding layer with the substrate surface. When repairing roller crusher spare parts, first pre-treat the damaged parts to remove surface oil, rust, fatigue layer, etc., and then transport the selected cladding material (such as wear-resistant alloy powder) to the laser beam action area through a powder feeding device. Under the action of the laser, the cladding material and the substrate surface melt and solidify rapidly to form a cladding layer with good performance.

3. Process flow of laser cladding technology to repair roller crusher spare parts

(I) Damage detection and evaluation
Use non-destructive testing technology (such as magnetic particle testing, ultrasonic testing, etc.) to detect the damage of roller crusher spare parts, determine the type, location, degree and scope of the damage, and provide a basis for the formulation of the repair plan.

(ii) Pretreatment before repair
The damaged part is machined to remove the fatigue layer and damaged tissue, so that the damaged part presents a regular geometric shape; then the damaged part is cleaned by sandblasting or pickling to remove impurities such as oil and rust, improve the surface roughness and cleanliness, and enhance the bonding strength between the cladding layer and the substrate.

(iii) Selection of cladding materials
According to the working conditions and performance requirements of the roller crusher spare parts, select suitable cladding materials. For spare parts that need to improve wear resistance, wear-resistant alloy powders such as cobalt-based and nickel-based can be selected; for spare parts that need to improve corrosion resistance, corrosion-resistant alloy powders such as stainless steel and nickel-chromium alloy can be selected.

(iv) Optimization of laser cladding process parameters
According to the characteristics of the cladding material, the shape and size of the damaged part, and the performance of the equipment, optimize the process parameters such as laser power, scanning speed, powder feeding speed, spot diameter, overlap rate, etc. to ensure the quality and performance of the cladding layer.

(V) Laser cladding repair
Fix the pre-treated spare parts on the workbench of the laser cladding equipment, adjust the distance and angle between the laser head and the surface of the spare parts, and perform laser cladding repair according to the optimized process parameters. During the cladding process, the quality and temperature of the cladding layer should be monitored in real time, and the process parameters should be adjusted in time to ensure the stability of the quality of the cladding layer.

(VI) Post-repair treatment
After the laser cladding repair is completed, the repaired spare parts are subjected to stress relief annealing to eliminate the residual stress of the cladding layer; then the cladding layer is processed by mechanical processing, grinding and other methods to meet the design size and surface accuracy requirements; finally, the repaired spare parts are subjected to surface treatment (such as painting, chrome plating, etc.) to improve their corrosion resistance and appearance quality.

4. Advantages of laser cladding technology in repairing roller crusher spare parts

(I) Improving the service life of spare parts
The cladding layer prepared on the damaged part by laser cladding technology has excellent wear resistance, corrosion resistance and fatigue resistance, which can significantly improve the service life of roller crusher spare parts and reduce the maintenance cost and downtime of equipment.

(ii) High repair accuracy
The laser beam has good focusing and directionality, which can achieve accurate repair of damaged parts, so that the size accuracy and shape accuracy of the repaired spare parts meet the design requirements, ensuring the assembly accuracy and operation stability of the equipment.

(iii) Small heat-affected zone
The heat input during the laser cladding process is small, and the heat-affected zone of the base material is small, which will not cause deformation of the base material and deterioration of the organizational properties, and can maintain the original performance and strength of the spare parts.

(iv) Green and environmentally friendly
Laser cladding technology does not produce pollutants such as waste gas, wastewater and waste residue during the repair process, which is environmentally friendly and meets the environmental protection requirements of modern industrial production.

As an advanced surface repair technology, laser cladding technology has significant advantages and broad application prospects in the repair of roller crusher spare parts. By reasonably selecting cladding materials and optimizing process parameters, damaged roller crusher spare parts can be effectively repaired, the operating efficiency and reliability of the equipment can be improved, and a strong guarantee can be provided for the stable development of industrial production. With the continuous development and improvement of laser cladding technology, it is believed that its application in the field of roller crusher spare parts repair will become more and more extensive and in-depth.