Industry faces the continual challenges of operating in less space and accelerating line speed in order to increase productivity, improve quality, and reduce cost. These challenges are particularly evident in the film and papermaking markets. To maintain competitive products in the market place, it is essential to incorporate rollers that are; lightweight, high stiffness, and compact. To satisfy these requirements, rolls made of carbon fiber reinforced plastics (hereinafter referred to CFRP) have proven effective and have come into wide use in many industrial fields. CFRP rolls are the structural materials that were developed mainly to improve the Young's modulus of rolls. Guiding and transfer rollers frequently require surface features such as non-adhesion and wear resistance. The typical surface treatments to CFRP currently employed are; painting, plating, and rubber lining or the like, but these treatments have their limits in the manufacturing process and effectiveness. Consequently, we have developed the technology to provide rolls with the desired surface by spraying various metals, ceramics, or cermets, directly on CFRP substrate. These sprayed rolls have been intensely monitored in actual operations to insure high speed capability and longevity. In this presentation, we will talk about the rotary bending fatigue test of CFRP rolls on which the carbide cermet was plasma-sprayed and the quality stability of the roll with the two-layer composites that was confirmed based on the test results.

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