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casting rollers
by Baudoin Loosen, S.A. ESAB N. V:, Belgium
There is no doubt that continuous casting has generally been introduced in steel
production plants. Continuous casting produces advantages in terms of production
time, production surface, energy savings, investments, production losses together
with much higher productivity.
Productivity is intlucnced by the
number of interruptions in production. These interruptions are
associated with the rate of roller
wear. Special attention has been
paid to the metallurgical aspects
of this wear and the economy of
reconditioning the rollers.
Roller wear
Roller wear has different causes.
The importance of the different
types of wear is also different as
the conditions in the different
parts of the continuous casting
machine can vary significantly.
The different causes can be described as follows.
The harsh enviroment in steel mills imposes rigorous demands on the materials
and products that are used.
In the lower parts of the installation, there is oxidation on the surface of the steel. This produces
oxides which can provoke high
abrasive wear.
Erosion
Worn rollers
Choice of welding
system
Different techniques can be used
to obtain the final surface of the
roller. Welding can be performed
with one wire or twin arc, with or
without a weaving system. Finally,
strip cladding with a strip width of
30 to 100 mm can be used. Depending on the dimensions of the
rollers, different systems have advantages or disadvantages.
Single wire welding is the most
common method and it can be
used on small and large rollers
but the productivity is low. Deposition rates between 5 and 9 kg/h
can be obtained with a welding
current of between 400 and 700
A. A weaving system produces
more uniform layers which are
easier to machine.
Twin-arc welding produces
much higher productivity. When
weaving is used, deposition rates
of between 10 and 18 kg/h are
possible with a welding current of
between 600 and 1,000 A. Usually
two wires with a diameter of 2,4
mm are used. With the weaving
system, beads with a width up to
60 mm can also be obtained on
the smallest roller with a diameter
of 200 mm. Bead appearance is
very good and very flat, so that
machining is easy.
The advantage of strip cladding
is that different widths can be
used on different roller diameters.
On small rollers, 30 mm strip is
used while strips of 60 up to 100
mm can be used on the larger
ones. Deposition rates of between
6 and 20 kg/h can be obtained.
Another advantage of strip cladding is the low percentage of dilution. This makes it possible to
eliminate the buffer layer. The
only inconvenience at the moment is that the flexibility when it
comes to obtaining special compositions is not as great as it is
with cored wires.
The final choice of welding
method has to be made after
taking account of all the economic aspects such as product cost,
deposition rate, dilution, surplus
thickness required for machining,
final cladding appearance and
susceptibility to defects. It is possible for one welder to control
two welding heads. This means
Welding procedure
Preheating temperature
Preheating the rollers is very important. The minimum temperature is 250C. The preheating
must be homogeneous throughout the surface. The best way to
do this is to put the rollers in an
oven at 300C. The temperature
should be measured with contact
thermocouples on different places
on the surface of the roller. Too
low a preheating temperature
could cause serious problems
during welding. The first layer
which has a lower chromium content and a higher carbon content
as a result of the dilution. will
quickly build up martensite and
can initiate cracks. With the second and third layers. these cracks
will grow and damage the roller.
Interpass temperature
After preheating, welding has to
start as quickly as possible.
During welding, the temperature
of the roller will rise due to the
heat input. The temperature
should be kept between 300C
and 450C. A higher temperature
will cause the welding quality of
the flux to deteriorate. A lower
temperature can produce martensite cracks. During welding. an air
cooling system can be placed just
in front of the place where the
welding is going to be performed.
Compressed air can be blown
onto the surface of the plate.
Never let the roller cool between
two layers. If work has to bc
interrupted for a long period (end
of the day), the roller has to be
placed in an oven at 300C until
welding can begin again. The best
way is to weld until all the cladding is finished.
Cooling
Quality improvement
Conclusion
The actual technique of cladding
o f the rollers has made it possible
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