ANSI AWS D14 7 D14 7M-2005 Recommended Practices for Surfacing and Reconditioning of Industrial Mill Rolls (1st Edition).pdf

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1、 550 N.W. LeJeune Road, Miami, FL 33126AWS D14.7/D14.7M:2005An American National StandardApproved by theAmerican National Standards InstituteOctober 19, 2005Recommended Practices forSurfacing and Reconditioningof Industrial Mill Rolls1st EditionPrepared by theAmerican Welding Society (AWS) D14 Commi

2、ttee on Machinery and EquipmentUnder the Direction of theAWS Technical Activities CommitteeApproved by theAWS Board of DirectorsAbstractThis standard provides guidance, based upon experience, for preparing, building up and overlaying by welding,postweld heat treating, finish machining, inspecting, a

3、nd record-keeping of new and reconditioned industrial mill rolls.Key WordsSurfacing, hardfacing, mill rolls, reconditioningAWS D14.7/D14.7M:2005iiInternational Standard Book Number: 0-87171-028-5American Welding Society550 N.W. LeJeune Road, Miami, FL 33126 2005 by American Welding SocietyAll rights

4、 reservedPrinted in the United States of AmericaPhotocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in anyform, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyrightowner.Authorizat

5、ion to photocopy items for internal, personal, or educational classroom use only or the internal, personal, oreducational classroom use only of specific clients is granted by the American Welding Society provided that the appropriatefee is paid to the Copyright Clearance Center, 222 Rosewood Drive,

6、Danvers, MA 01923, tel: (978) 750-8400; Internet:.iiiAWS D14.7/D14.7M:2005Statement on Use of AWS American National StandardsAll standards (codes, specifications, recommended practices, methods, classifications, and guides) of the AmericanWelding Society (AWS) are voluntary consensus standards that

7、have been developed in accordance with the rules of theAmerican National Standards Institute (ANSI). When AWS standards are either incorporated in, or made part of,documents that are included in federal or state laws and regulations, or the regulations of other governmental bodies,their provisions c

8、arry the full legal authority of the statute. In such cases, any changes in those AWS standards must beapproved by the governmental body having statutory jurisdiction before they can become a part of those laws andregulations. In all cases, these standards carry the full legal authority of the contr

9、act or other document that invokes theAWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWSstandard must be by agreement between the contracting parties.AWS American National Standards are developed through a consensus standards development p

10、rocess that bringstogether volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the processand establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, orverify the accuracy of any information or t

11、he soundness of any judgments contained in its standards.AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whetherspecial, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or relianceon

12、this standard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any informationpublished herein.In issuing and making this standard available, AWS is not undertaking to render professional or other services for or onbehalf of any person or entity. Nor is AWS undertaking t

13、o perform any duty owed by any person or entity to someoneelse. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek theadvice of a competent professional in determining the exercise of reasonable care in any given circumstances.This standard may b

14、e superseded by the issuance of new editions. Users should ensure that they have the latest edition.Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard acceptany and all liabilities for infringement of any patent or trade name items. AWS d

15、isclaims liability for the infringement ofany patent or product trade name resulting from the use of this standard.Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.On occasion, text, tables, or figures are printed incorrectly, const

16、ituting errata. Such errata, when discovered, are postedon the AWS web page (www.aws.org).Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request,in writing, to the Managing Director, Technical Services Division, American Welding Socie

17、ty, 550 N.W. LeJeune Road,Miami, FL 33126 (see Annex B). With regard to technical inquiries made concerning AWS standards, oral opinionson AWS standards may be rendered. However, such opinions represent only the personal opinions of the particularindividuals giving them. These individuals do not spe

18、ak on behalf of AWS, nor do these oral opinions constitute officialor unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as asubstitute for an official interpretation.This standard is subject to revision at any time by the AWS D14 Committee

19、on Machinery and Equipment. It must bereviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations,additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should beaddressed to AWS Headquart

20、ers. Such comments will receive careful consideration by the AWS D14 Committee onMachinery and Equipment and the author of the comments will be informed of the Committees response to thecomments. Guests are invited to attend all meetings of the AWS D14 Committee on Machinery and Equipment toexpress

21、their comments verbally. Procedures for appeal of an adverse decision concerning all such comments areprovided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained fromthe American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.This page is

22、intentionally blank.ivAWS D14.7/D14.7M:2005vAWS D14.7/D14.7M:2005Personnel*AdvisorAWS D14 Committee on Machinery and EquipmentJ. L. Warren, Chair CNH America LLCD. J. Malito, 1st Vice Chair Girard Machine Company, IncorporatedL. L. Schweinegruber, 2nd Vice Chair Robinson Industries, IncorporatedP. H

23、owe, Secretary American Welding SocietyD. B. Ashley Hartford Steam Boiler Inspection telephone (305) 443-9353; fax (305) 443-5951; e-mail infoaws.org; orvia the AWS web site .This page is intentionally blank.viiiAWS D14.7/D14.7M:2005ixAWS D14.7/D14.7M:2005Table of ContentsPage No.PersonnelvForeword

24、viiTable of Contents.ixList of Tables .xiList of Figures.xii1. Scope.12. Normative References .12.1 AWS References12.2 ASTM References .13. Definitions 34. Base Materials for Rolls, Arbors, Sleeves, and Fabricated Journals .34.1 Overview34.2 Chemical Composition 34.3 Weldability 44.4 Mechanical Prop

25、erties .44.5 Thermal Processing .55. Surface Preparation 55.1 General.55.2 Stress Relieving Prior to Processing55.3 Surface Condition 55.4 Methods of Cleaning55.5 Inspection after Cleaning.65.6 Premachining for Welding.65.7 Inspection after Machining65.8 Documentation and Reporting.66. Welding Consu

26、mables.66.1 Overview66.2 Flux Types .76.3 Wire Electrodes .77. Properties of Weld Deposits .77.1 General.77.2 Properties and Composition of Buildup Materials 77.3 Properties and Composition of Overlay Materials 98. Welding Techniques and Process Control 118.1 Overview118.2 Preheat and Interpass Temp

27、erature118.3 Body Run-Off Rings138.4 Welding Parameters.138.5 Considerations Specific to Journal Repair, Buildup, or Overlay.208.6 Postweld Heat Treatment.22xPage No.AWS D14.7/D14.7M:20059. Procedure Qualification and Tests 239.1 Procedure Qualifications (WPS)239.2 Procedure Qualifications (PQR)239.

28、3 Type of Tests Required2310. Repair and Correction 3310.1 General.3310.2 Examples of Nonconformance 3310.3 Purchasers and Manufacturers Obligations.3311. Finish Machining and Final Inspection.3311.1 Setup 3311.2 Rough Machining 3311.3 In-Process Inspection.3311.4 Final Machining.3411.5 Final Inspec

29、tion .3411.6 Nonconformance3411.7 Documentation and Reporting.3412. Quality Assurance .3412.1 General.3412.2 Quality System Outline .34Annex A (Informative)Flux and Wire Consumables .37Annex B (Informative)Guidelines for Preparation of Technical Inquiries for AWS Technical Committees41Annex C (Infor

30、mative)Recommended Forms43Annex D (Informative)Bibliography51List of AWS Documents on Machinery and Equipment53xiAWS D14.7/D14.7M:2005List of TablesTable Page No.1 Typical Chemical Composition and Mechanical Properties of Typical Forged Roll Materials42 Carbon Equivalent and Associated Preheat Tempe

31、ratures of Typical Forged Materials 53 Typical All-Weld-Metal Compositions Used for Industrial Mill Rolls.84 Typical Properties of Low Alloy Buildup Materials Deposited Using Neutral SAW Fluxes .95 Hardness (HRC) as a Function of Heat Treatment for 12% Cr Stainless and Tool Steel Overlays(4 Hours at

32、 Temperature).96 Tensile Properties as a Function of Temperature for Some Stainless Overlays 107 Impact Toughness of Some Stainless Steel Overlays 108 Typical Parameters for Tubular Submerged Arc Wires.149 Wire Feed Speed to Travel Speed Ratios Which Produce a Weld Buildup Cross-SectionalArea of abo

33、ut 0.06 in.240 mm2.1410 Suggested Electrode Displacement from Roll Top Dead Center.1811 Calculated Cr Content of Various Layers of Overlay vs. Dilution for a Flux-WireCombination Producing 13% Cr All-Weld-Metal .1912 Sample Types vs. Qualification Levels2413 Welding Process Variables 24xiiAWS D14.7/

34、D14.7M:2005List of FiguresFigure Page No.1 Typical Roll Types and Nomenclature 22 View of Typical Roll Cross Section 33 Preheat Temperature as a Function of Carbon and Alloy Content 124 Required Soak Time at Temperature to Heat the Roll Through Its Diameter as a Function of Diameter.125 Preheat Temp

35、erature Effect on Roll Diameter Expansion.136 Overlay Beads Deposited at Wire Feed Speed (wfs) to Travel Speed Ratio of 5 to 1,1/8 in. 3.2 mm Wire Diameter, 28 Volts DCEP157 Overlay Beads Deposited at 180 ipm 76 mm/sec Wire Feed Speed, 1/8 in. 3.2 mmWire Diameter, Varying Voltage .168 Overlay Beads

36、Deposited at Wire Feed Speed (wfs) to Travel Speed Ratio of 5 to 1,1/8 in. 3.2 mm Wire Diameter, 28 Volts DCEN .169 Effect of Stepover at 100 ipm 42 mm/sec Wire Feed Speed (480 A) with 1/8 in. 3.2 mmWire, DCEP .1710 Effect of Electrode Position on Bead Shape, Slag Spillage, and Flux Spillage.1811 Ef

37、fect of Lead Position on Bead Solidification Lines1912 Stepover Techniques 2213 Basic Bead on Plate Sample for Level 1 Qualification2714 Roll Cylinder Sample for Level 1, 2, or 3 Qualification2715 Roll Qualification TestsQualification of HardfacingLocation of Rockwell HardnessTest Samples 1A1, 2B1,

38、2C1 .2716 Roll Qualification TestsQualification of HardfacingSample Layout and General Description 2817 Roll Buildup Qualification TestsSample Roll Configuration Prior to Welding 2918 Roll Buildup Qualification TestsQualification of BuildupLocation of Test Samples .3019 Level 1 Tensile Test for Jour

39、nal and Buildup Materials3120 Roll Qualification TestsQualification of HardfacingLocation of Chemical AnalysisSamplesSample 1A1 32List of FormsForm Page No.C.1 Sample Form for Incoming and Final Inspection Records 44C.2 Sample Form for Welding Procedure Specification 45C.3 Sample Form for Procedure

40、Qualification Record 46C.4 Sample Form for Welder and Welding Operator Qualification Test Record 47C.5 Sample Form for Recording Weld Processing Parameters48AWS D14.7/D14.7M:200511. ScopeAn industrial mill roll can be defined as any roll or cylin-drical body that transports, processes, guides or per

41、formsa function in creating a product in the heavy metals,paper, plastic, or lumber industries. These rolls can comein many shapes and sizes (as shown in Figure 1), andinclude, but are not limited to, table rolls, guide rolls,caster rolls, pinch rolls, leveler rolls, straightener rolls,bridle rolls,

42、 and blocker rolls.This standard provides guidance, based upon experience,for preparing, building up and overlaying by welding,postweld heat treating (PWHT), finish machining,inspecting, and record-keeping of new and reconditionedindustrial mill rolls. While mainly used in the primarymetal-working i

43、ndustry, industrial mill rolls are alsoused in other applications. Because common practicepredominately employs submerged arc welding (SAW),this document emphasizes SAW. However many of theprinciples are applicable, with suitable modifications, togas metal arc welding (GMAW), flux cored arc welding(

44、FCAW), and electroslag cladding.This standard makes use of both U.S. Customary Unitsand the International System of Units (SI). The measure-ments may not be exact equivalents; therefore each sys-tem should be used independently of the other withoutcombining in any way. The designation D14.7 uses U.S

45、.Customary Units. The designation D14.7M uses SIUnits. The latter are shown in appropriate columns intables and figures or within brackets . Detailed dimen-sions on figures are in inches. A separate tabular formthat relates the U.S. Customary Units with SI Units maybe used in tables and figures.Safe

46、ty and health issues and concerns are beyond thescope of this standard, and therefore are not fullyaddressed herein. Safety and health information is avail-able from other sources, including, but not limited to,ANSI Z49.1, Safety in Welding, Cutting, and Allied Pro-cesses, and applicable federal and

47、 state regulations.Welding symbols shown on drawings should be compat-ible with those shown in AWS A2.4, Standard Symbolsfor Welding, Brazing, and Nondestructive Examination.Special conditions or deviations should be fully ex-plained by added notes, details, or definitions.2. Normative ReferencesThe

48、 following standards contain provisions which,through reference in this text, constitute provisions ofthis AWS standard. For undated references, the latestedition of the referenced standard shall apply. For datedreferences, subsequent amendments to, or revisions of,any of these publications do not a

49、pply.2.1 AWS References11. AWS A2.4, Standard Symbols for Welding, Brazing,and Nondestructive Examination2. AWS A3.0, Standard Welding Terms and Definitions3. AWS A5.17, Specification for Carbon Steel Elec-trodes and Fluxes for Submerged Arc Welding4. AWS A5.23, Specification for Low Alloy SteelElectrodes and Fluxes for Submerged Arc Welding5. AWS B4.0, Standard Methods for MechanicalTesting of Welds2.2 ASTM References21. ASTM A 388, Standard Practice for UltrasonicExamination of Heavy Steel Forgings1AWS standards are