Steel Mill Roll Degradation Uneven Wear Patterns with Thin Slab Casters

Steel Mill Roll Degradation

Higher Wear Rates For Thin Slab Caster Rolls

Thin Slab Caster Rolls have been shown to wear by an average of 0.22mm/MT. This is higher with conventional casters worldwide where wear rates as low as 0.05mm/Mt have been reported. The increased rate of roll rotation translates into a higher frequency of thermal and mechanical loading during service than experienced in a conventional caster. Therefore, service within a thin slab caster is more serve than in a conventional slab caster.

Comparison between Conventional and Thin Slab Casters

Parameter	Conventional	Thin Slab
Length of 1M tonne slab, m	485,290	1,358,811
Roll Diameter, mm	230	165-185
Slab Width, mm	1250	1250
Slab thickness, mm	210	75
Casting Speed, m/mm	1	4.5
N Roll Revolutions / minute	1.38	7.7 (185mm Ø) 8.6 (165mm Ø)
No Roll Revolutions million tonnes	671,349	2620,297 (165mm Ø) 2,337,021 (185mm Ø)

Equivalent performance on conventional caster.

Tonnage
For equivalent cast length, m.	For equivalent No roll revolutions
1,904,000	2,654,060

Uneven Wear Patterns with Thin Slab Casters

Roll wear and cracking in Thin Slab Casters is non-uniform. The degree of cracking and wear generally increases from the unloaded edge of the rolls towards the "hot end" of the rolls supporting the slab centre. Inspection and reclamation of spit rolls within a thin slab caster must take into account this non-uniform wear and depth of cracking

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Caster Rolls Conventional

Caster Rolls Thin Slab

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