Enhancing Efficiency and Longevity of Cold Rolling Process Through Hard-Chrome Coatings: A Comparative Study

Efficiency in rolling processes relies heavily on the durability of rolls, a critical tool in the operation. However, dynamic rolling under high loads often results in frequent roll wear, leading to reduced productivity, efficiency, and substantial capital losses. This study investigates the application of zinc and hard chrome coatings to the EN19 substrate in cold rolling process, verified through Energy Dispersive X-ray Spectroscopy (EDS) and X-ray Diffraction (XRD) analyses. Experimental tests on a pin-on-disk wear machine reveal mass wear rates: Hard chrome, Zinc, and EN19 at 1.67 x 10^-07, 3.33 x 10^-07, and 25.33 x 10^-07 (gm/Nm) respectively. Hard chrome exhibits superior performance, lasting 15.19 times longer than EN19 and twice as long as zinc. Zinc extends EN19's life by 7.6 times. Scanning Electron Microscopy (SEM) images show adhesive and abrasive wear as the primary causes of roll wear. Hard chrome coating stands out as an effective solution to significantly extend roll life, minimizing capital and time losses associated with roll wear. Additionally, hard chrome offers low friction and excellent corrosion resistance, making it a promising choice for enhancing cold rolling process efficiency and cost-effectiveness.