Roll for use in a hot dip coating line

Abstract

A continuous coating line includes a roll assembly exposed to molten metal. The roll assembly includes a roll rotatable relative to a bearing block. The roll includes a roll portion and a journal protruding from each end of the roll portion. The roll is made from a refractory ceramic material that is resistant to wear, abrasion, and corrosion when the roll is exposed to the molten metal.

Claims

1. A roll for use in a continuous coating line, wherein the roll comprises a generally cylindrical roll portion extending along a longitudinal axis, wherein the roll comprises at least about 90% of a refractory ceramic material; wherein the roll comprises a channel extending inwardly from each end of the roll along the longitudinal axis, wherein each channel is sized to extend through an end portion of each end of the roll such that each channel does not extend through an entire length of the roll along the longitudinal axis; wherein the roll comprises a support rod positioned within each channel wherein each support rod is sized to extend through the end portion of each end of the roll such that each support rod does not extend through an entire length of the roll along the longitudinal axis; and wherein each support rod is positioned within the roll such that each support rod is enclosed within the roll and does not extend beyond an end surface of the roll.

2. The roll of claim 1, wherein the refractory ceramic material comprises a select one or more of silicon carbide, alumina, and fused silica.

3. The roll of claim 2, wherein the roll comprises between about 5% and about 100% of silicon carbide.

4. The roll of claim 2, wherein the roll comprises between about 5% and about 100% of alumina.

5. The roll of claim 1, wherein the roll is castable.

6. The roll of claim 1, wherein the roll comprises a journal extending outwardly from each end of the roll portion along the longitudinal axis, wherein the journal is generally cylindrical, wherein the outer diameter of each journal is smaller than the outer diameter of the roll portion.

7. The roll of claim 6, wherein the roll portion and each journal are a solid integral component.

8. The roll of claim 6, wherein the roll comprises a tapered surface positioned between the roll portion and each journal.

9. The roll of claim 8, wherein the tapered surface is convex.

10. The roll of claim 6, wherein the roll comprises a fillet positioned between the roll portion and each journal.

11. The roll of claim 6, wherein the journal is insertable within a bore of a bearing block such that the journal is rotatable within the bore.

12. The roll of claim 11, wherein the bearing block is ceramic.

13. The roll of claim 11, wherein the bearing block and the journal form a plain bearing such that an outer surface of the journal is in direct contact in an interior surface of the bore of the bearing block.

14. The roll of claim 1, wherein each support rod is sized to be positioned within the respective channel of the roll by a friction fit.

15. The roll of claim 1, wherein the refractory ceramic material is configured to extend continuously across a diameter of the roll at a central portion of the roll.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) The accompanying figures, which are incorporated in and constitute a part of this specification, illustrate embodiments, and together with the general description given above, and the detailed description of the embodiments given below, serve to explain the principles of the present disclosure.

(2) FIG. 1 depicts a schematic view of a configuration of a coating portion in a continuous steel processing line.

(3) FIG. 1A depicts a schematic view of an alternative configuration for the coating portion of FIG. 1.

(4) FIG. 2 depicts a partial cross-sectional front view of a prior art roll for a roll assembly that may be used in the coating portion of FIG. 1.

(5) FIG. 3 depicts a photo of the prior art roll of FIG. 2, showing degradation of the roll after being submersed within molten metal.

(6) FIG. 4 depicts a perspective view of a roll assembly comprising refractory ceramic material for use with the coating portion of FIG. 1

(7) FIG. 5 depicts a perspective view of a bearing block of the roll assembly of FIG. 4.

(8) FIG. 6 depicts a perspective view of a roll of the roll assembly of FIG. 4.

(9) FIG. 7 depicts a front view of the roll of FIG. 6.

(10) FIG. 8 depicts an end view of the roll of FIG. 6.

(11) FIG. 9 depicts a front view of an alternative embodiment for the roll of the roll assembly of FIG. 4.

(12) FIG. 10 depicts a partial cross-sectional view of an end portion of the roll of FIG. 9.

(13) FIG. 11 depicts a partial cross-sectional view of the end portion of the roll of FIG. 9, showing a support rod inserted within the roll.

(14) FIG. 12 depicts a front view of an alternative embodiment for the roll of the roll assembly of FIG. 4.

(15) FIG. 13 depicts a photo of a plurality of fused silica rods prior to insertion within a molten aluminum bath.

(16) FIG. 14 depicts a cross-sectional view of the plurality of fused silica rods of FIG. 13 after insertion within the molten aluminum bath.

DETAILED DESCRIPTION

(17) The present application generally relates to structures and/or methods for incorporating a refractory ceramic material within a roll assembly of a continuous coating line. In such a configuration, it has been found that the presence of the refractory ceramic material may reduce wear on the roll assembly and may also reduce the propensity of the roll assembly to be subject to chemical attack from the molten metal.

I. EMBODIMENTS OF A ROLL ASSEMBLY COMPRISING REFRACTORY CERAMIC MATERIAL

(18) A roll assembly incorporating refractory ceramic materials is discussed in more detail below. Because such a roll assembly may reduce wear, corrosion, and/or abrasion of the roll assembly, it should be understood that any element of such a roll assembly may be incorporated into any one or more roll assemblies in a continuous coating line. These roll assemblies may include, but are not limited, to any stabilizing and correcting roll assemblies (40), sink roll assemblies (42), deflector roll assemblies (50), and/or pot roll assemblies (70) as described above.

(19) Referring to FIG. 4, roll assembly (100) comprises two bearing blocks (110) and a roll (120). Each bearing block (110) is generally configured to receive at least a portion of roll (120) to promote rotation of roll (120) relative to bearing block (110). Although not shown, it should be understood that each bearing block (110) may be generally coupled to a fixture or other structure to hold each bearing bock (110) in position within hot dip tank (20).

(20) An illustrative bearing block (110) is best seen in FIG. 5. As can be seen, bearing block (110) includes a generally octagonal body (112). The octagonal shape of body (112) is generally configured to provide surfaces by which a fixture or other structure can attach to bearing block (110) to position bearing block (110) within hot dip tank (20). Although body (112) of the present example is shown with octagonal structure, it should be understood that in other examples other suitable structures may be used such as square, hexagonal, triangular, circular, and/or etc.

(21) Regardless of the particular shape used for body (112), body (112) defines a receiving bore (114) through the center of bearing block (110). Receiving bore (114) is defined by a generally cylindrical shape. As will be described in greater detail below, receiving bore (114) is configured to receive at least a portion of roll (120) to permit roll (120) to freely rotate within bore (114). Accordingly, a portion of an exterior surface of each journal (126) is in direct contact with a portion of an interior surface of bore (114) of bearing block (110). Bearing block (110) may thereby form a plain bearing with each journal (126) without the use of rollers or rolling bodies. Each journal (126) may then be rotated within a stationary bearing block (110). Bearing block (110) may comprise a refractory material, such as ceramic, as will be discussed in more detail below.

(22) Referring to FIGS. 6-8, roll (120) of roll assembly (100) comprises a roll portion (122) and a journal (126) extending from each side of roll portion (122). Roll portion (122) comprises a generally elongate cylindrical shape extending longitudinally along axis (A). The cylindrical shape of roll portion (122) is generally configured to receive steel sheet (60) to permit at least a portion of steel sheet (60) to wrap around at least a portion of roll portion (122). Thus, it should be understood that a width of roll portion (122) generally corresponds to the width of steel sheet (60) such that the width of roll portion (122) is wider than steel sheet (60). This may compensate for strip tracking through coating portion (10). Roll portion (120) may have an outer diameter of between about 4 inches and 20 inches, such as between about 9 inches and 10 inches, though other suitable dimensions can be used.

(23) As described above, each journal (126) extends outwardly from roll portion (122) along longitudinal axis (A). Each journal (126) comprises a generally cylindrical shape with an outer diameter that is less than the outer diameter defined by roll portion (122). Each journal (126) is sized to be received by bore (114) of a respective bearing block (110). As best seen in FIG. 7, a tapered surface (124) in the illustrated embodiment is positioned between roll portion (122) and journal (126). A chamfer or fillet (123) is also positioned between roll portion (122) and tapered surface (124), and chamfer or fillet (125) is positioned between tapered surface (124) and journal (126). In some versions, tapered surface (124) is omitted such that only a chamfer or fillet is positioned between the roll portion (122) and the journal (126). Tapered surface (124) and/or fillets (123, 125) may thereby distribute stress more uniformly between roll portion (122) and journal (126) to reduce a potential mechanical stress concentration. Tapered surface (124) and/or fillets (123, 125) may also prevent wear on bearing block (110) if journal (126) translates within bearing block (110) such that an outer surface of bearing block (110) comes into contact with an outer surface of roll (120). Roll (120) may comprise a refractory material, such as ceramic, as will be discussed in more detail below.

(24) Another embodiment of a roll (220) is shown in FIGS. 9-11 that may be incorporated into roll assembly (100). Roll (220) is substantially similar to roll (120), except that roll (220) comprises a pair of support rods (240). As best seen in FIG. 9, roll (220) comprises roll portion (222) and journal (226) extending from each side of roll portion (222). Roll portion (222) comprises a generally elongate cylindrical shape extending longitudinally along axis (A). The cylindrical shape of roll portion (222) is generally configured to receive steel sheet (60) to permit at least a portion of steel sheet (60) to wrap around at least a portion of roll portion (222).

(25) As described above, each journal (226) extends outwardly from roll portion (222) along longitudinal axis (A). Each journal (226) comprises a generally cylindrical shape with an outer diameter that is less than the outer diameter defined by roll portion (222). Each journal (226) is sized to be received by bore (114) of a respective bearing block (110). In the illustrated embodiment, a convex surface (224) is positioned between roll portion (222) and journal (226). Convex surface (224) may distribute stress more uniformly between roll portion (222) and journal (226) and/or reduce wear on bearing block (110). Though it should be noted that convex surface (224) is merely optional and other suitable surfaces may be used, such as straight and/or tapered surfaces.

(26) Referring to FIGS. 10-11, roll (220) defines a channel (230) extending within each end of roll (220) along longitudinal axis (A) of roll (220). In the illustrated embodiment, channel (230) extends through journal (226) and into a portion of roll portion (222). Channel (230) may have a length of about 14 inches and a diameter of about 1.23 inches, but other suitable dimensions can be used. A support rod (240) may thereby be inserted within channel (230) of roll (220). Support rod (240) may be sized to correspond to the length and/or diameter of channel (230) such that support rod (240) is friction fit within channel (230). Of course, other suitable methods may be used to couple support rod (240) with channel (230), such as with a threadable coupling and/or adhesive. Support rod (240) may be made from steel or other suitable material to increase strength to roll (220). Support rod (240) thereby extends through roll (220) between journal (226) and roll portion (222) to help support any mechanical stress concentrations between journal (226) and roll portion (222). Roll (220) may comprise a refractory material, such as ceramic, as will be discussed in more detail below. Accordingly, in some embodiments, the assembled roll (220) comprises at least about 90% refractory ceramic material. Still other suitable configurations for roll (220) will be apparent to one with ordinary skill in the art in view of the teachings herein.

(27) Another embodiment of a roll (320) is shown in FIG. 12 that may be incorporated into roll assembly (100). Roll (320) is substantially similar to roll (220), except that roll (320) comprises a steel core (330). As best seen in FIG. 12, core (330) comprises roll portion (332) and journal (336) extending from each side of roll portion (332). Core (330) may then be cast with a refractory material about the entire surface of core (330) to form an outer roll portion (322) and an outer journal (326) extending from each side of outer roll portion (322). For instance, the outer diameter of roll portion (332) of core (330) may be about 18.5 inches and the outer diameter of outer roll portion (322) may be about 22 inches to correspond to a refractory material thickness of about 2.25 inches, though other suitable dimensions may be used. In some other versions, the refractory material may be cast only on the roll portion (332) of core (330) and a sleeve comprising refractory material may be added as a separate component about journals (336). Examples of such sleeves are provided in U.S. patent application Ser. No. 15/583,450 entitled “Method for Extending the Campaign Life of Stabilizers for a Coating Line,” filed on May 1, 2017, the disclosure of which is incorporated by reference herein.

(28) Each bearing block (110) and/or roll (120, 220, 320) of roll assembly (100) may comprise a refractory material, such as ceramic, that has high strength and is resistant to wear at high temperature. This refractory ceramic material may additionally have a low coefficient of thermal expansion, resistance to thermal shock, resistance to wetting by molten metal, resistance to corrosion, and is substantially chemically inert to molten metals. Such a refractory ceramic material may comprise silicon carbide (SiC), alumina (Al.sub.2O.sub.3), fused silica (SiO.sub.2), or combinations thereof. In some versions, the refractory ceramic material comprises between about 5% and about 100% silicon carbide and/or alumina.

(29) By way of example only, suitable refractory ceramic materials may include a class of ceramics known as SiAlON ceramics. SiAlON ceramics are high-temperature refractory materials that may be used in handling molten aluminum. SiAlON ceramics generally exhibit good thermal shock resistance, high strength at high temperatures, exceptional resistance to wetting by molten aluminum, and high corrosion resistance in the presence of molten non-ferrous metals. Such a SiAlON ceramic may comprise CRYSTON CN178 manufactured by Saint-Gobain High-Performance Refractories of Worcester, Mass., although numerous SiAlON class ceramics may be used.

(30) Other suitable refractory ceramic materials may include a ceramic having about 73% Al.sub.2O.sub.3 and about 8% SiC. This ceramic may comprise GemStone 404A manufactured by Wahl Refractory Solutions of Fremont, Ohio. In another embodiment, a harder ceramic having a greater amount of SiC, such as about 70% SiC, may be used. In some versions, stainless steel wire needles may be added to the ceramic material, such as about 0.5 percent to about 30 percent by weight of the material. Such a ceramic may comprise ADVANCER nitride bonded silicon carbide manufactured by Saint-Gobain Ceramics of Worcester, Mass. or Hexology silicon carbide also manufactured by Saint-Gobain Ceramics of Worcester, Mass. Accordingly, bearing blocks (110) and roll (120, 220) may be made from the same refractory material or bearing blocks (110) and roll (120, 220) may be made from different refractory material. Still other suitable refractory materials will be apparent to one with ordinary skill in the art in view of the teachings herein.

(31) Each bearing block (110) and/or roll (120, 220, 320) may be made by casting the refractory ceramic material. In some other versions, bearing block (110) and/or roll (120, 220) may be made by pouring liquid ceramic into a mold and using heat to bake the ceramic to remove moisture. An outer surface of the bearing block (110) and/or roll (120, 220) may then be grinded to provide a smooth outer surface. Still other suitable methods to make the components of roll assembly (100) will be apparent to one with ordinary skill in the art in view of the teachings herein.

III. METHOD OF OPERATION

(32) Roll assembly (100) may be assembled as shown in FIG. 4. For instance, each journal (126) of roll (120) may be inserted within a bore (114) of a corresponding bearing block (110). Accordingly, a portion of an exterior surface of each journal (126) is in direct contact with a portion an interior surface of bore (114) of bearing block (110). Bearing block (110) may thereby form a plain bearing with each journal (126) without the use of rollers. Each journal (126) may then be rotated within a stationary bearing block (110).

(33) In an exemplary use, steel sheet (60) may be manipulated through coating portion (10) by roll assembly (100). For instance, steel sheet (60) may wrap around roll (120) of roll assembly (100). Friction between steel sheet (60) and roll portion (122) of roll (120) may cause roll (120) to rotate as steel sheet (60) move relative to roll assembly (100). Rotation of roll (120) thereby causes corresponding rotation of each journal (126) within a respective bearing block (110).

(34) The refractory ceramic material of journal (126) and/or bearing block (110) may provide resistance to wear between journal (126) and bearing block (110), as well as resistance to thermal shock and/or corrosion. The refractory ceramic material of roll portion (122) may also provide resistance to wear of roll portion (122) from rotation of steel sheet (60), as well as resistance to thermal shock and/or corrosion. Roll assembly (100) may thereby increase the life of coating portion (10) to increase efficiency and/or reduce costs of the coating line. Accordingly, by forming the components of roll assembly (100) from a refractory ceramic material, roll assembly (100) may better withstand and resist mechanical erosion and cavitation than a steel surface or a steel surface with a thermal spray coating. The refractory material of roll assembly (100) thereby prolongs the service life of roll assembly (100).

(35) It will be understood various modifications may be made to this invention without departing from the spirit and scope of it. Therefore, the limits of this invention should be determined from the appended claims.

III. EXAMPLES

(36) A series of tests were performed to evaluate roll assemblies. This series of tests is detailed below in the following Examples. It should be understood that the following examples are merely for illustrative purposes and that in other instances, various alternative characteristics may be used as will be understood by those of ordinary skill in the art in view of the teachings herein.

Example 1

(37) Static dip testing of fused silica rods in a Type II aluminum coating bath was conducted. Fused silica round bars were used having a diameter of about 2.4 inches. The initial test was a 30-day immersion test. During the test, the fused silica underwent a full transformation, via a reduction reaction, to alumina. Neither loss of diameter, nor signs of chemical attack, were evident. There was also no wetting of the molten aluminum on the refractory surface. It was thereby determined that fused silica and/or alumina show a much greater resistance to material loss via chemical attack by molten aluminum to extend the life of rolls formed from fused silica and/or alumina.

Example 2

(38) Static dip testing of fused silica rods in a Type II aluminum coating bath was conducted. Fused silica round bars were used having a diameter of about 2.4 inches. These bars are shown in FIG. 13 prior to immersion. After 9 days of immersion, a thin conversion layer of about 0.040 inches about the circumference of the bars was revealed where the fused silica was converted to alumina, as shown in FIG. 14. Again, neither loss of diameter, nor signs of chemical attack, were evident. There was also no wetting of the molten aluminum on the refractory surface. It was thereby determined that fused silica and/or alumina show a much greater resistance to material loss via chemical attack by molten aluminum to extend the life of rolls formed from fused silica and/or alumina.

Example 3

(39) A load test was performed on a roll made from a single piece of solid Gemstone 404A ceramic material at room temperature. The roll portion of the roll had a length of about 76 inches and a diameter of about 10 inches. The journal of the roll had a length of about 4.5 inches and a diameter of about 4 inches. A load of about 650 lbf. was determined to be a maximum operating load for each journal. A load of about 1,300 lbf. was then applied to each journal. This load was increased in about 650 lbf. increments to a maximum load of about 3,650 lbf. Once the maximum load was reached and held for several minutes, the test was stopped. Both journals withstood this loading with no indications of cracking. Accordingly, it was determined that the ceramic roll was able to withstand the applied load in a coating line with a safety factor of about 5.5 above the determined maximum operating load.

Example 4

(40) A roll test was performed on a roll made from fused silica. The roll was assembled with a steel bearing block and ran about 430,000 feet of steel. There was no significant loss of diameter on the roll journals or the body, but there was significant wear in the steel bearing block. While the bearing material was not suitable, the test of the roll was considered to be successful.

Example 5

(41) A roll test was performed on a roll made from fused silica. The roll was assembled with a bearing block made from Gemstone 404A. The roll barrel diameter was about 10 inches. The roll was removed from the metal bath after running about 680,000 feet of steel. Based on a visual inspection of the roll, there appeared to be no significant wear between the roll and bearings and the roll was placed back into service. The roll then experienced failure after running about 780,000 feet of product. Upon removal, it was determined that both journals had fractured and separated from the roll. While the test of the roll was considered to be successful, the bearing material was considered to be too aggressive.