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Wear Resistance in Continuous Caster Rollers |
| | | | South Africa
Rollers in the continuous casting plant were welded with Weldclad 3 overlay. The Weldclad 3 rollers outperformed previous rollers by 300%. It was decided that all 230mm and 300mm diameter rollers would be welded with Weldclad 3. |
| | Europe
Wear results of rolls welded with Weldclad 3 are given in the table below: |
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Segment Identification |
Roll Diameter (mm) |
Wear per 100,000 Tonnes (mm)
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A |
220 |
0.030 |
|
B |
240 |
0.018 |
|
C |
280 |
0.015 |
|
D |
300 |
0.013 |
|
E |
300 |
0.042 |
|
F |
300 |
0.035 | |
| | | This low rate of wear means that the rolls are only removed from the caster after 3,600,000 tonnes of production. The rolls are then machined back 2mm and returned to the caster for a second campaign. |
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Mexico
Weldclad 3 is being used to clad full body rollers, and has significantly improved the life of the rollers over the previous products used.
The caster is of an old design, and the roller base materials are also of an old style material. The use of Weldclad 3 rollers meant the rollers started to last longer, and consequently the primary mode of failure changed for one of wear to one of roll bending. After consultation with Corewire it was decided to use Weldclad 75 as a buffer material prior to hardfacing with Weldclad 3. The rollers welded with the combination of materials are now beginning to come out of the caster for their re-welding, and both bending and crack depth have been reduced. |
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China
Rollers were supplied into a new caster from a European roll manufacturer, and using a Weldclad consumable designed for 2 layer welding.
The casting plant managers are extremely pleased with these rollers. The first campaign achieved 1,700,000 tonnes, after which the rollers were removed during a scheduled maintenance period. Their condition was such that they required only a 2mm dressing from the surface before they were returned to service. The rollers then performed a second campaign of 1,700,000 tonnes before again been taken out during a maintenance period. They were dressed a second time and are now in the caster on their third campaign.
The total steel through put achieved by these same rolls is now approaching 5 million tonnes. |
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