Dry Sliding Wear Investigation of Hard Chrome and Nickel Coating on En19 for Rolling Application

Abstract

In the heavy sheet metal industry, in cold rolling process rolls are typically made of EN19 steel. Due to the severe loading and pressure conditions experienced during cold rolling of steel sheet causes wear and failure of the rolls. Enhancing the life of these rolls under such demanding operating conditions necessitates the application of coatings on EN19. This paper focuses on investigating the effectiveness of Hard Chrome and Nickel alloy coatings on Engineering Steel (EN19) through a comparative sliding wear experimental study. The research examines the impact of Hard Chrome and Nickel coatings on the properties of EN19. Various characterization techniques, including X-ray diffraction (XRD), surface roughness analysis, hardness testing, scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS), are employed to evaluate the coatings. The wear tests are conducted under standard operating conditions to determine the improvement in roll life achieved through the coatings. The results reveal that the Hardchrome coating exhibits greater hardness and wear resistance compared to the Nickel coating and the EN19 base material. Nickel gives 9.49 times more life than substrate EN19 whereas Hardchrome gives 15.19 times more life than substrate EN19 and 1.6 times more life than Nickel coating. The findings suggest that applying Hard Chrome to EN19 rolls can effectively enhance their durability and prevent failure. The experimental investigation presented in this study provides valuable insights into the selection and performance of coatings for improving the longevity of rolls in heavy sheet metal rolling processes.