Roller Hardfacing
Machine -- WLD-WL-2000
Continuous twin-head chromium carbide overlay welding system, purpose-built for continuous casting rollers, mill rollers, and cylindrical wear-critical components. Engineered on imported core technology and refined through years of domestic application experience.
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Max Length2000 mm
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Max DiameterΦ500 mm
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Max Weight2000 kg
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Current1250 A
Purpose-Built for Continuous
Caster & Mill Roller Overlay.
Ergonomic layout, stable operation, simple maintenance, and advanced PLC-driven process technology -- engineered for high-volume roller hardfacing under demanding industrial conditions.
The WLD-WL-2000 is a complete continuous roller welding overlay platform combining mechanical structure, motion control, welding process control, fume extraction, and remote operation -- all delivered as one engineered system.
- Beam frame structure
- Vertical torch slide
- Horizontal torch slide
- Mobile flux storage tank
- Water-cooled torch system
- Power transmission unit
- Wire spool platform & rotator
- Fume extraction ducting
- Variable speed wire feeder
- Water-cooled welding torch
- Integrated electrical cabinet
- Wireless handheld remote
Smart Control. Stable Feed.
Simple Operation.
Full-digital PLC process control with motion control technology. Auto parameter setup and storage. Pre-configured ring, step, and wave overlay programs for caster & mill rollers.
10.2" HD touchscreen HMI with TECO digital torch trajectory display. One operator can supervise multiple machines through clear process windows.
Dual active drive rollers handle multiple wire diameters. Higher feed torque and speed stability -- optimized for flux-cored wires, matching imported equipment performance.
Dedicated fume duct per torch, consolidated through fan exhaust. Removes the majority of welding fume from open-arc self-shielded overlay processes.
Smooth linear guideways and integrated control system. Easy installation, simple maintenance, and a low documented failure rate over long-term operation.
Welding Processes & Intelligent Control.
- Open-arc overlay welding
- Submerged-arc overlay welding
- Oscillation overlay
- Ring (circumferential) overlay
- Spiral overlay
- Position memory during overlay
- Self-stabilizing torch tip
- Adaptive welding regulation
- High-speed stable oscillation overlay
- Increased penetration & deposition rate
- Auto recording of all process parameters
- Wireless remote operation
- TECO PLC main controller
- 10.2" touchscreen HMI (CN/EN)
- CANopen / Modbus / RS-232
- Panasonic A6 servo on X-axis
- SANYO drive on Z-axis
- Auto calculation from input parameters
Flat-characteristic control technology developed specifically for hardfacing duty. Continuous-use rated, high anti-interference design, and one of the highest market-share power sources in the overlay welding industry.
Engineered Drive Train.
Precision Motion Control.
- Variable speed motor
- Chrome-hardened reducer
- Slewing bearing
- SUN 3-jaw self-centering chuck
- X-axis stroke control unit
- Panasonic A6 AC servo motor
- Planetary reducer
- Linear guideways
- Annealed & CNC-machined frame
- Dual-drive gear-rack X-axis (Grade 7)
- Precision ball-screw drive
- SANYO driver + OPG stepper
- Z-axis stepper control unit
- Torch displacement & oscillation
- Full-area roller coverage
Model WLD-WL-2000
Engineering Data.
Verified parameters covering capacity, motion accuracy, welding output, and overall envelope dimensions.
| No. | Item | Parameter |
|---|---|---|
| 01 | Model | WLD-WL-2000 |
| 02 | Welding Function | Submerged-arc / Open-arc Overlay |
| 03 | Max Length | 2000 mm |
| 04 | Max Diameter | Φ500 mm |
| 05 | Max Overlay Workpiece Diameter | Φ500 mm |
| 06 | Max Weight | 2000 kg |
| 07 | Footprint | L10000 × W2000 × H23500 mm |
| 08 | Oscillation Width | 5-50 mm |
| 09 | Oscillation Speed | 0.1-3.5 m/min |
| 10 | Roller Rotation Speed | 0.05-0.3 r/min |
| 11 | Voltage | 0-45 V |
| 12 | Current | 30-1250 A |
| 13 | XY-Axis Travel Accuracy | ±0.1 mm |
| 14 | Torch Lifting Accuracy | ±0.1 mm |
| 15 | Oscillation Accuracy | ±0.01 mm |
| 16 | Welding Thickness Accuracy | ±0.5 mm |
| 17 | Equipment Dimensions (L×W×H) | 8000 × 3750 × 1500 mm (above ground) |
| 18 | Equipment Color | Blue |
Engineered Process Flow
for Mill & Caster Rollers.
Rollers operate under high temperature and cyclic load. The overlay layer must combine high-temperature strength, thermal fatigue resistance, and abrasion resistance -- supported by full pre-heat, controlled welding, and post-weld heat treatment.
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01Roller Roughing
Pre-machining of base roller
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02Ultrasonic Test
Defect inspection of base metal
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03Pre-Heating
350-400 °C
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04SAW Overlay
Auto submerged-arc with insulation
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05PWHT
~600 °C × 6 h soak
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06Finish Machining
Roller surface finishing
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07Hardness Test
Overlay hardness verification
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08UT & Release
Final UT & warehouse release
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SAW WireSolid Φ4 mm or flux-cored Φ3.2 mm
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Sintered FluxSJ107 or SJ108
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Equipment SetJHM-1250 welder · annealing furnace · holding furnace · 3-head auto overlay machine · flux recovery unit
- Pre-heat Temperature ~350-400 °C
- Welding Current 400-800 A
- Arc Voltage 28-35 V
- Wire Stick-out 30-40 mm
- Inter-pass Temperature 150-200 °C
- PWHT Annealing ~600 °C × 6 h
Process includes transition layer welding and controlled bead overlap to ensure metallurgical bond, uniform structure, and consistent overlay thickness.
Need a Roller Overlay Solution?
Get WLD-WL-2000 specs & quote.
Share your roller dimensions, base material, expected overlay layer, and production volume. Our engineers respond within 8 hours with a tailored process and equipment proposal -- including consumable matching and turnkey line layout where required.