Tool Type: Rollforming roller
Work Material: .039" thick painted 2024 aluminum coil
Original Tooling Material: D-2 tool steel hardened to RC 60-62
Problem: The continuous flow of the aluminum sheet over the D-2 rollers, caused premature wear of one of the corners on the roller. This premature wear resulted in the product being out of specifications after production of 75,000 feet. Examination of the roller corner revealed that the wear was caused by the breakdown of the larger carbide particles.
Solution: Upgrade to Z-Wear PM tool steel hardened to RC 60-62
Results: Due to the fine-grained microstructure produced by the PM process and the higher wear resistance of the Z-Wear PM chemical composition, the roller was able to maintain the sharpness of the corner for the production of 250,000 feet of coil.