Wear prevention measures for aluminum sheaves (guide rolls) with Dycron.
We received your inquiry regarding the severe wear of the guide roll (sheave) for the carrier rope that guides the paper in the dry part of the paper machine at your paper manufacturing company. This wear frequently causes the rope to come off, disrupting production. Issues: 1. Since the carrier rope rotates alone, we would like to reduce wear by changing the sheave from aluminum to iron or stainless steel, but the increased weight makes this change impossible. 2. We considered hard chrome plating, but it cannot be applied to aluminum substrates. (Direct electrolytic plating on aluminum is not feasible, so a base plating must be applied first, which increases the risk of peeling when hard chrome plating is done on top.) 3. We want to maintain wear resistance even under high temperatures due to heat exposure. 4. Frequent replacements incur manufacturing and replacement costs.
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We propose "Dikron" (electrolytic hard chromium carbide plating), which can be processed directly on aluminum and has better wear resistance than hard chrome plating. Points: 1. Dikron has a hardness of around Vickers HV1000, making it very hard with extremely high wear resistance. * Hard chrome plating is around HV800. 2. Direct plating is possible with simple surface preparation. 3. The substrate for the sieve can be reused. 4. Even when used at high temperatures, there is little reduction in hardness, and wear resistance can be maintained. (At 300°C, it is around HV900... whereas hard chrome plating softens to around HV400.)
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