Brand New Single Tooth Roller Manufacturing and Hardfacing Refurbishment

Single-tooth rollers are important crushing components in sintering plants. During operation, the working surface of the roller teeth is continuously exposed to high-temperature material impact, severe abrasive wear, and repeated compression.

Over extended operation, the roller teeth may gradually experience:

• Reduction of tooth thickness
• Changes in tooth profile
• Increased working clearance
• Reduced crushing efficiency

Due to their large size and complex structure, the wear resistance of the roller teeth directly affects the operating cycle of the equipment.

Depending on the actual condition, single-tooth rollers are generally handled through two approaches:

• Manufacturing new wear-resistant roller teeth according to customer drawings;
• Refurbishing worn single-tooth rollers by hardfacing to restore the working surface.

New Single Tooth Roller Teeth Manufacturing Process

For new single-tooth roller projects, WODON manufactures roller teeth and designs the wear-resistant layer according to customer drawings, dimensions, and operating conditions.

The overall process mainly includes:

• Roller teeth manufacturing
• Hardfacing overlay application
• Surface machining
• Dimensional inspection

Since operating conditions vary between different applications, the roller tooth structure and wear protection design need to be matched with the actual working environment.

Roller Tooth Manufacturing

The roller teeth are the main components directly involved in the crushing process. Their structural design affects:

• Material crushing performance
• Load distribution
• Wear pattern
• Operational stability

Compared with conventional wear parts, roller teeth need to achieve a balance between:

• Sufficient structural strength
• Good impact resistance
• Stable wear-resistant surface performance

WODON can manufacture individual roller teeth according to customer drawings or technical specifications and design the hardfacing layer based on the specific wear conditions.

The tooth body adopts a reinforced design and is protected with a 20–35 mm thick wear-resistant overlay. This specially designed wear layer can withstand temperatures up to 800°C while resisting continuous impact conditions. It provides a balanced combination of hardness and toughness.

Chromium Carbide Overlay Protection for Single Tooth Roller Teeth

After roller tooth manufacturing, the working surface usually requires additional wear protection.

For severe wear applications, chromium carbide overlay (CCO) is a commonly used surface hardfacing technology.

Through the hardfacing process, wear-resistant alloy materials containing elements such as chromium and carbon are deposited onto the roller tooth surface, forming a composite wear-resistant layer.

The performance of the overlay is influenced by multiple factors, including:

• Alloy composition design
• Carbide formation
• Overlay thickness
• Welding parameters
• Cooling and solidification conditions

For single tooth roller applications, wear layer design is not simply focused on achieving maximum hardness. A proper balance between abrasion resistance and impact resistance is essential.

Large Single Tooth Roller Processing Case

For large single tooth roller projects, WODON performs roller tooth manufacturing and hardfacing processing according to the provided roller dimensions.

The roller dimensions of this project:

Roller blank size: 8 m × 1.2 m diameter

The project scope includes:

• Roller tooth manufacturing
• Hardfacing on roller tooth surfaces
• Wear layer processing
• Final dimensional inspection

For large wear components, material selection alone is not sufficient. Welding process control and machining accuracy also influence the final performance of the component.

Hardfacing Refurbishment of Worn Single Tooth Rollers

In addition to manufacturing new single tooth roller teeth, WODON also provides hardfacing refurbishment services for worn single tooth rollers.

When the main roller structure remains suitable for continued operation and the wear is mainly concentrated on the working surface, the worn area can be rebuilt through hardfacing.

The refurbishment process generally includes:

Wear Condition Evaluation

Before repair, the worn roller needs to be evaluated to determine:

• Wear location
• Wear severity
• Condition of the original structure
• Required restoration dimensions

Based on the evaluation results, engineers can determine whether hardfacing repair is suitable.

Surface Preparation and Hardfacing Repair

After surface preparation, a new wear-resistant layer is deposited onto the worn area through the hardfacing process.

The main objectives of refurbishment include:

• Restoring the roller tooth profile
• Rebuilding worn areas
• Improving surface wear resistance

The specific refurbishment method depends on the actual wear condition and operating requirements.

New Manufacturing or Hardfacing Refurbishment: How to Choose?

The appropriate approach for a single tooth roller depends on its actual condition.

New Manufacturing May Be Suitable When:

• The original roller teeth are severely damaged;
• A new tooth structure is required;
• The original design no longer meets current operating conditions.

Hardfacing Refurbishment May Be Suitable When:

• The roller body remains structurally intact;
• Wear is mainly concentrated on the working surface;
• The original dimensions and performance can be restored through hardfacing.

For large industrial wear components, accurately evaluating the wear condition is an important step in selecting between new manufacturing and refurbishment.