Novotroitsk Branch of NUST MISIS, Novotroitsk, Russia
S. P. Nefedyev, Dr. Phys.-Math., Prof., Dept. of Metallurgical Technologies and Equipment, Faculty of Metallurgical Technologies, e-mail: sergeynefedyeff@gmail.com

Kherson Technical University, Genichesk, Russia¹ ; Nosov Magnitogorsk State Technical University, Magnitogorsk, Russia²
M. V. Kharchenko, Cand. Eng., Associate Prof., Dept. of Mechanical Engineering, Faculty of Engineering and Transport¹, Associate Prof., Dept. of Mechanics, Institute of Metallurgy, Mechanical Engineering and Materials Processing², e-mail: kharchenko.mv@bk.ru

R. R. Dema, Dr. Eng., Prof., Dept. of Mechanical Engineering, Faculty of Engineering and Transport¹, Associate Prof., Dept. of Metal Forming Machines and Technologies, Institute of Metallurgy, Mechanical Engineering and Materials Processing², e-mail: demar78@mail.ru

Kherson Technical University, Genichesk, Russia
A. V. Grubnik, Cand. Eng., Associate Prof., Dept. of Mechanical Engineering, Faculty of Engineering and Transport

NUST MISIS, Moscow, Russia
O. R. Latypov, Cand. Eng., Researcher, Dept. of Metal Forming, e-mail: latolegraf@list.ru

Fedorovsky Polar State University, Norilsk, Russia
Yu. R. Faskhitdinova, Postgraduate Student, Dept. of Metallurgical Machines and Equipment, e-mail: yuliya.galimova.17@mail.ru

The paper investigates the restoration and enhancement of the durability of loop lifter rolls in section mills using plasma-powder surfacing. A comparative analysis of coatings produced with different materials is carried out: flux-cored wire PP-NP-35V9Kh3SF (composition A), PG-10R6M5-type powder without (composition B) and with an addition of 50 % tungsten carbide (composition C), and coated electrodes of the T-590 grade (composition D). The microstructure and hardness of the obtained coatings are examined. It is shown that the application of plasma-powder surfacing with tungsten carbide addition ensures the formation of a wear-resistant structure. It is demonstrated that plasma-powder surfacing with PR-10R6M5 powder results in a dendritic-cellular austenitic-martensitic structure with a developed eutectic carbide phase and a hardness of up to 65 HRC. The additional introduction of 50 % tungsten carbide promotes the formation of a composite coating with inclusions of undissolved WC particles and chromium carbides of the M7C3 type in the boundary zones, leading to an increase in hardness up to 71–72 HRC and maximum wear resistance among the compositions studied. Coated samples were tested for hardness and abrasive wear resistance in accordance with GOST 23.208-79 and ASTM B611. The test results established that coating composition C surpasses traditional materials (including T-590 electrode surfacing and Kh12 steel) in terms of wear resistance. The wear rate decreases to 0.082 mg/m, and the relative wear resistance reaches 12.1 (1/mg/m), confirming the effectiveness of the selected composition. Production trials at the 170, 370, and 450 section mills demonstrated an increase in the durability of loop lifter rolls by 20-24 % (or 3.3-6.6 thousand tons of rolled product).
This research was supported by the Russian Science Foundation (RSF) grant No. 25-79-31018, https://rscf.ru/project/25-79-31018/. Part of the work was carried out at NUST MISIS with the support of the Postdoc Program under Priority 2030 (grant No. K4-2025-3).

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