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Ultra deep hardening layer, the core highlight of MC5 with a full life can be achieved in one quenching, with a single-sided effective hardening layer of up to 40mm, far superior to traditional MC3 (3% Cr) and Cr2 series (about 10-15mm). This means that the wear-resistant layer on the roll surface is thicker, the wear rate is slower, and the ideal roll shape can be maintained for a long time without the need for intermediate quenching, which not only avoids the deformation risk of secondary heat treatment, but also greatly shortens the downtime maintenance time, especially suitable for copper foil rolling mills with high requirements for continuity and accuracy.
High rigidity support, locking thin specifications and high precision as support rollers, its core function is to provide strong support for the work roller, suppress elastic flattening and deflection during compression. The high compressive strength and rigidity of MC5 material can effectively stabilize the deformation of the roll system, ensuring precise control of thickness tolerance and plate shape (such as convexity control within 0.3mm range) when rolling ultra-thin copper foil (such as ≤ 6 μ m), reducing defects such as edge waves and center waves, and improving the yield of finished products.
Strong wear resistance and anti peeling, suitable for high-speed and harsh working conditions, copper foil rolling speed is fast, unit pressure is high, and the requirements for roller surface wear resistance and fatigue resistance are extremely high. The dispersed M ₇ C Ⅲ type carbides on the MC5 matrix have a hardness of up to 1500-1800HV, and the particles are small and uniform, which can significantly improve wear resistance and contact fatigue strength, effectively resist high-speed friction and thermal stress, reduce surface peeling, microcracks and indentation, and extend service life.
The manufacturing is stable and the full life performance is consistent. The electric slag remelting+forging process is adopted, and the MC5 roll billet has a dense structure, high purity, and less internal inclusions and segregation. Combined with precise heat treatment and precision machining (such as non-destructive testing, dynamic balancing, mirror polishing), it can ensure uniform hardness and structure of the entire roller surface, low vibration and noise during operation, further ensuring the smoothness and dimensional stability of the copper foil surface.
element | C | Si | Mn | P | S | Cr | Ni | V | Mo |
scope | 0.85-0.95 | 0.25-0.45 | 0.2-0.4 | ≤0.025 | ≤0.025 | 4.8-5.4 | ≤0.2 0 | 0.1-0.2 | 0.2-0.4 |
Deep hardened layer: With a Cr content of about 5%, it has extremely strong hardenability and an effective hardened layer depth of up to 40mm (radial), far exceeding traditional 9Cr2Mo materials.
High hardness and wear resistance: The working layer of the roller body has a hardness of 75~85 HSD (about 62~66 HRC), and the carbides are mainly small M ₇ C Ⅲ (hardness of 1500~1800 HV), with excellent wear resistance.
Strong accident resistance: With excellent toughness, thermal shock resistance, and fatigue resistance, it can effectively prevent accidents such as steel sticking, peeling, and cracking.
Long service life: The millimeter rolling capacity is much higher than that of ordinary Cr2 and Cr3 series rollers, and the full life cycle cost is lower.
Raw materials: Made of ESR steel ingots with high purity and minimal segregation.
Process: Three way forging+large forging ratio (≥ 3-4), fully crushing coarse carbides, refining grains, ensuring uniform and dense structure.
Purpose: To eliminate internal looseness, liquid precipitated carbides, and banded structures, and improve the strength and anti peeling properties of the roller body.
Pre treatment after forging: High temperature diffusion annealing (≥ 1050 ℃), uniform composition.
Quenching: Heat in sections to 930~980 ℃, fully insulate and then oil quench to ensure the depth of the hardened layer.
Low temperature tempering: holding at 150-200 ℃ for a long time, eliminating internal stress, stabilizing structure and size.
The rolling of copper foil (especially lithium battery copper foil, with a thickness often<12 μ m) requires extremely strict requirements for the rolling mill and rolling mill:
Supporting function: As a supporting roller, it provides rigid support for the working roller, withstands hundreds to thousands of tons of rolling pressure, and ensures the stability of the roller system.
Ensure board shape: high hardness and high precision (cylindricity ≤ 2 μ m) roller surface, effectively control the flatness of the board shape, and prevent copper foil from having edge waves, middle waves, and warping.
Ensuring surface quality: Excellent wear resistance ensures that the roller surface maintains a mirror finish (Ra ≤ 0.2 μ m) for a long time, avoiding roller marks, scratches, and pitting on the copper foil surface.
High stability: The deep quenched hard layer ensures that after long-term use (repeated regrinding), the hardness of the roller body does not significantly decrease, and the performance is stable and consistent.
Hardness: Roller body 78~82 HSD; Roll neck 40~50 HSD (balancing strength and toughness).
Hardened layer: effective depth (≥ 75 HSD) ≥ 35-40mm.
Ultrasonic testing: 100% ultrasonic testing (GB/T 13314), with no internal defects.
Accuracy: Dimensional accuracy IT5~IT6, form and position tolerances (roundness, cylindricity, runout) ≤ 0.001~0.003mm.
Rolling of lithium battery copper foil: After rolling the raw foil, it is required to have a clean surface and no pinholes. The MC5 support roller is processed with high cleanliness and wear-resistant characteristics, suitable for high-speed continuous production.
High frequency/high-frequency copper foil: Ultra thin copper foil for 5G communication, with strict requirements for plate shape and thickness uniformity. The high rigidity and stability of MC5 ensure rolling accuracy.
Wide copper foil: Rolled with a large width (≥ 600mm), the MC5 support roller has high rigidity and bending resistance, effectively controlling edge thinning and warping.
Multiple varieties of copper alloys: covering purple copper, brass, phosphor copper, etc. The universality and wear resistance of MC5 are suitable for multi material switching production.
