GUIDE Roll defects Cluster Mill Rolls

1(46)

CONTENT

1. CRACKING

1.1 Cracking in network

1.2 Longitudinal cracking

1.3 Helicodial Cracking

2. SPALLING

2.1 Microspalling of thermal origin

2.2 Microspalling of mechanical origin

12

2.3 Spalling

15

3. RUPTURE OF THE BARREL

17

3.1 Radial rupture of the barrel

17

3.2 Helicoidal rupture of the barrel

20

3.3 Longitudinal rupture of the barrel

24

4. RUPTURE OF THE NECK

27

4.1 Drive end rupture (roll dogs)

27

4.2 Drive end ruptures (splines)

29

5.1 Indentation

31

5.2 Lines

32

5.3 Grinding defects

33

5.4 Irregular surface finsh on the strip

37

6. FORMATION MECHANISMS

39

6.1 Surface fatigue

39

6.2 Damage due to overheating

42

6.3 Consequenses of a rolling incident

45

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1. Cracking
1.1 Cracking in network
ROLL TYPE
All
GRADE
All
DESCRIPTION
Presence of several cracks in a network, or mosaic pattern.
In most cases, the structure and hardness are modified.
POSSIBLE CAUSE(S)
Thermal shock caused by a rolling incident (sticking, slippage, blockage of the rolls, rupture of the
oil film) or a grinding mishap.
The rise in temperature, above that of the heat treatment, modifies the microstructure and the
balance of internal stresses. Cracks are produced by stress relaxation.
CORRECTIVE ACTIONS
Record all rolling and grinding incidents on the roll record card.
Remove all cracks, work hardening or overheated areas completely before putting the roll back in
service.
Carry out a non-destructive test (dye penetrant, Eddy current, magnetic particle, ultrasonic) to
make sure that the defects are eliminated.

Fig. 1 Detected with magnetic particle test

Fig. 2 Detected with Catella etching

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Fig. 3 Detected with dye penetrant

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1.2 Longitudinal cracking

ROLL TYPE
All
GRADE
All
DESCRIPTION
Longitudinal crack(s) on the barrel of a work roll (fig.1) or on a 2nd intermediate roll (fig.2).
POSSIBLE CAUSE(S)
Local overheating provoked by a bearing seizure (fig.2).
Local overheating provoked by an incident (fig. 3 ).
Incomplete elimination of a crack that appeared during a previous campaign.
If the defect appears very early during the first campaign: delayed quench cracking (fig.1).
CORRECTIVE ACTIONS
Record all rolling and grinding incidents on the roll record card.
Remove all cracks, work hardening or overheated areas completely before putting the roll back in
service.
Carry out a non-destructive test (dye penetrant, Eddy current, magnetic particle, ultrasonic) to
make sure that the defects are eliminated.

Fig. 1 Delayed quench cracking

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Fig. 2 Local overheating bearing seizure

Fig. 3 Local overheating incident, detected by Magnaflux

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ROLL TYPE
All
GRADE
All
DESCRIPTION
Cracks on roll face, starting from the roll centre and developing towards the outside, with friction
marks (fig.1).
POSSIBLE CAUSE(S)
Friction from the thrust rings.
CORRECTIVE ACTIONS
Modify the thrust rings.

Fig. 1 Cracks on roll face

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1.3 Helicodial Cracking

ROLL TYPE
Intermediate rolls
GRADE
All
DESCRIPTION
An isolated continuous crack, typical of a torsional stress that develop in a spiral pattern on a part
or on the whole barrel.
POSSIBLE CAUSE(S)
Thermal chock caused by a rolling incident (sticking, slippage, blockage of the rolls, rupture of the
oil film) or a grinding mishap. The rise in temperature, above that of the heat treatment, modifies
the microstructure and the balance of internal stresses. Cracks are produced by stress relaxation.
Incomplete elimination of a crack that appeared during a previous campaign.
Surface fatigue starting points.
Problem with the dogs when the cracking starts from the drive end.
CORRECTIVE ACTIONS
Record all rolling and grinding incidents on the roll record card.
Remove all cracks, work hardening or overheated areas completely before pitting the roll back in
service.
Carry out a non-destructive test (dye penetrant, Eddy current, magnetic particle, ultrasonic) to
make sure that the defects are eliminated.
When the cracking starts from the drive end:
Check and adjust the safety components settings (pins, rings)
Check the sleeve (play/wear ) and the drive-end dimensions.
Reduce to a minimum the setting time of the mill rapid opening device.
In the case of systematic rupture, consider the possibility of lowering* the roll dogs hardness.

Fig. 1, After dye penetrant

Fig. 2

*NOTE: However, if the roll dogs hardness is too low, galling or deformations may occur and cause play in
coupling, vibrations and possibly chatter marks on the strip.
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Fig. 3 After Magnaflux

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2. Spalling
2.1 Microspalling of thermal origin
ROLL TYPE
All
GRADE
All
DESCRIPTION
Spalling with cracks either parallel or in network and with a lower hardness.
POSSIBLE CAUSE(S)
Thermal shock caused by a rolling incident (sticking, slippage, blockage of the rolls, rupture of the
oil film) or a grinding mishap. The rise in temperature, above that of the heat treatment, modifies
the microstructure and the balance of internal stresses. Cracks are produced by stress relaxation.
CORRECTIVE ACTIONS
Remove all cracks, work hardening or overheated areas completely before putting the roll back in
service.
Record all rolling and grinding incidents on the roll record cards.
Carry out a non-destructive test (dye penetrant, Eddy current, magnetic particle, ultrasonic) to
make sure that the defects are eliminated.

Fig. 1 After dye penetrant

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Fig. 2 After dye penetrant

Fig. 3 After Catella etching

Fig. 4

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Fig. 5, After Magnaflux

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2.2 Microspalling of mechanical origin

ROLL TYPE
All (Intermediate rolls in particular)
GRADE
All
DESCRIPTION
Spalling not very deep, with a particular rupture face (a dull face) corresponding to the maximum
shearing stresses zone and with/or without cracks and rise in the metal hardness (work hardening).
Example: cone junction on 1st intermediate rolls or back up pressure area on 2nd intermediate
rolls.
POSSIBLE CAUSE(S)
Mechanical origin: surface fatigue phenomenon associated with an excessive and/or accumulated
work hardening.
Runs too long and insufficient grinding.
Normal run but compression stress exceeding the steel properties.
CORRECTIVE ACTIONS
Remove all cracks, work hardening or overheated areas completely before putting the roll back in
service.
Record all rolling and grinding incidents on the roll record cards.
Carry out a non-destructive test (dye penetrant, Eddy current, magnetic particle, ultrasonic) to
make sure that the defects are eliminated.
Restore the original hardness.
Turn to high speed steel grades for the work rolls.
Modify the grinding policy in quantity and in the frequency.

Fig. 1

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Fig. 2

Fig. 3

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Fig. 4

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2.3 Spalling
ROLL TYPE
All
GRADE
All
DESCRIPTION
Damage with small spalls having different depth due to a surface fatigue phenomenon.
The face of the rupture presents propagation fronts.
- elliptical, perfectly concentric (fig. 3)
- with a more confuse aspect together with very small bracelets (fig. 1-2).
POSSIBLE CAUSE(S)
Residual cracking
Mechanical origin: excessive and accumulated work hardening leading to a surface fatigue
phenomenon (intermediate or support rolls).
Thermal origin: rolling or grinding incidents, thermal shock (cracking in network).
Combined mechanical and thermal origin (fig. 1-2).
Metallurgical origin: inclusions (fig.3).
CORRECTIVE ACTIONS
Record all rolling and grinding incidents on the roll record cards.
Remove all cracks, work hardening or overheated areas completely before putting the roll back in
service.
Carry out a non-destructive test (dye penetrant, Eddy current, magnetic particle, ultrasonic) to
make sure that the defects are eliminated.

Fig. 1

Fig. 2
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Fig. 3

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3. Rupture of the barrel

3.1 Radial rupture of the barrel
ROLL TYPE
Work rolls
GRADE
All
DESCRIPTION
Rupture of the work roll perpendicular to the axis (fig.1).
Sticking of the rolled strip around the rupture area (fig.2).
Dull and granulous aspect of the rupture zone without visible starting points (fig.3).
POSSIBLE CAUSE(S)
Excessive bending caused by mill incident.
The rupture could have started from a crack, formed during a previous run and not correctly
eliminated, by concentration of stresses set up on the crack.
CORRECTIVE ACTIONS
Record all rolling and grinding incidents on the roll record cards.
Remove all cracks, work hardening or overheated areas completely before putting the roll back in
service.
Carry out a non-destructive test (dye penetrant, Eddy current, magnetic particle, ultrasonic) to
make sure that the defects are eliminated.

Fig. 1

Fig. 2
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Fig. 3

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ROLL TYPE
All
GRADE
All
DESCRIPTION
Rupture by fatigue perpendicular to the roll axis.
Aspects of the rupture:
Starting point at the surface (A).
Very visible concentric propagation fronts (fig. 1-2) or not so visible (fig.3) but
corresponding to a gradual cracking (B).
Brutal final rupture (C).
POSSIBLE CAUSE(S)
Cracks not completely eliminated by grinding, which propagated during previous runs under cyclic
bending stresses.
The origin of the cracking may be:
Surface fatigue.
Thermal fatigue (following a mill or grinding incident).
CORRECTIVE ACTIONS
Record all rolling and grinding incidents on the roll record card.
Remove all cracks, work hardening or overheated areas completely before putting the roll back in
service.
Carry out a non-destructive test (dye penetrant, Eddy current, magnetic particle, ultrasonic) to
make sure that the defects are eliminated.

Fig. 1

Fig. 2

Fig. 3

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3.2 Helicoidal rupture of the barrel

ROLL TYPE
2nd intermediate drive rolls
GRADE
All
DESCRIPTION
Rupture of the barrel provoked by a spiral cracking that may have been initiated by a mechanical or
a thermal surface defect (fig.2).
Dull and granulose aspect of the rupture zone without propagation fronts (fig.3).
POSSIBLE CAUSE(S)
Excessive and combined bending and torsional stresses.
Retained mechanical or thermal cracks.
CORRECTIVE ACTIONS
Check and adjust the safety components settings (pins, rings ).
Record all rolling and grinding incidents on the roll record card.
Remove all cracks, work hardening or overheated areas completely before putting the roll back in
service.
Carry out a non-destructive test (dye penetrant, Eddy current, magnetic particle, ultrasonic) to
make sure that the defects are eliminated.

Fig. 1

Fig. 2

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Fig. 3

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ROLL TYPE
All
GRADE
All
DESCRIPTION
Rupture by fatigue in a spiral pattern (fig.1) with starting points on the surface (fig.2).
Presence of several concentric propagation fronts (B) tracing the development of the rupture.
POSSIBLE CAUSE(S)
Cracks not correctly eliminated during the grinding operation, which propagated under excessive
bending in previous runs.
The origin of the cracking may be:
- Surface fatigue.
- Thermal fatigue (following a mill or grinding incident).
CORRECTIVE ACTIONS
Record all rolling and grinding incidents on the roll record card.
Remove all cracks, work hardening or overheated areas completely before putting the roll back in
service.
Carry out a non-destructive test (dye penetrant, Eddy current, magnetic particle, ultrasonic) to
make sure that the defects are eliminated.

Fig. 1

Fig. 2

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Fig. 3

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3.3 Longitudinal rupture of the barrel

ROLL TYPE
All
GRADE
All
DESCRIPTION
Brutal rupture of the barrel in two parts.
Granulose and dull aspect of the rupture zone with the presence of oxide and calamine.
POSSIBLE CAUSE(S)
Longitudinal cracking that propagated when putting the rolls in the mill under rolling stresses.
Delayed quench cracking starting from the threaded centre.
CORRECTIVE ACTIONS
Record all rolling and grinding incidents on the roll record card.
Remove all cracks, work hardening or overheated areas completely before putting the roll back in
service.
Carry out a non-destructive test (dye penetrant, Eddy current, magnetic particle, ultrasonic) to
make sure that the defects are eliminated.

Fig. 1 Face of a longitudinal rupture of a work roll

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ROLL TYPE
All
GRADE
All
DESCRIPTION
Rupture by fatigue.
Presence of several propagation fronts parallel to the axis (A).
POSSIBLE CAUSE(S)
Cracks not correctly eliminated during the grinding operation, which propagated under cyclic
rolling stresses in previous runs.
The origin of the cracking may be:
- Surface fatigue.
- Thermal fatigue (following a mill or grinding incident).
Example: overheating due to the contact of the back up roller with the 2nd intermediate drive roll.
CORRECTIVE ACTIONS
Record all rolling and grinding incidents on the roll record card.
Remove all cracks, work hardening or overheated areas completely before putting the roll back in
service.
Carry out a non-destructive test (dye penetrant, Eddy current, magnetic particle, ultrasonic) to
make sure that the defects are eliminated.

Fig. 1

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Fig. 2

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4. Rupture of the neck

4.1 Drive end rupture (roll dogs)
ROLL TYPE
2nd Intermediate drive roll
GRADE
All
DESCRIPTION
Rupture of one, several or all teeth (fig.1) that may lead to the rupture of the barrel (fig.2).
Brutal rupture without start points or propagation fronts (fig.3)
POSSIBLE CAUSE(S)
Excessive stress provoked by a sudden stop of the mill.
Over-dimensioned safety components (pins, rings ).
Teeth hardness specification is too high.
Faulty drive-end sleeve.
CORRECTIVE ACTIONS
Check and adjust the safety components settings (pins, rings ).
Check the sleeve (play/wear ) and the drive end dimension.
Reduce to a minimum the setting time of the mill rapid opening device.
In the case of systematic rupture, consider the possibility of lowering* the hardness of the roll dog.

Fig. 1

Fig. 2

*NOTE: However, if the roll dogs hardness is too low, galling or deformations may occur and cause play in
coupling, vibrations and possibly chatter marks on the strip.
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Fig. 3

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4.2 Drive end ruptures (splines)

ROLL TYPE
2nd Intermediate drive rolls
GRADE
All
DESCRIPTION
Rupture of a part or all of the splines.
POSSIBLE CAUSE(S)
Insufficient mechanical characteristics (hardness specification).
Driving torque applied only on one part of the drive-end:
- Incomplete introduction of the drive sleeve (fig.1)
- Wear (fig.2).
- Sleeve geometry.
Surface fatigue leading to a cracking (fig. 3-4).
CORRECTIVE ACTIONS
Check the drive sleeve and the splines (wear, geometry).
Increase the specified hardness values.
Make sure that the drive sleeve is fully introduced.

Fig. 1

Fig. 2
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Fig. 3

Fig. 4

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5. Marks on the barrel / strip

5.1 Indentation
ROLL TYPE
Work rolls
GRADE
All
DESCRIPTION
Local depressions on the surface of the barrel.
POSSIBLE CAUSE(S)
Foreign body on the strip.
Barrel hardness is too low or the first intermediate hardness too high.
Soft areas following a local overheating.
CORRECTIVE ACTIONS
Remove all the defects that occurred during the previous run.
Improve the cleanliness / filtration of the lubricant.
Increase the roll hardness specification or decrease that of the 1st intermediate rolls.

Fig. 1

Fig. 2
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5.2 Lines
ROLL TYPE

Work rolls

GRADE

All

DESCRIPTION
Lines on the roll parallel to the axis (from a mm to a few cm).
POSSIBLE CAUSE(S)
Local overheating or overpressure (small cracks).
Carbides removed from the roll surface during grinding or texturing.
CORRECTIVE ACTIONS
Remove all the defects that were formed during the previous run.
Re-define the metallurgical specifications (for example powder metallurgy).

Fig. 1, After Magnaflux

Fig. 2

Fig. 3, Microphotography after Nital etching

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5.3 Grinding defects

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Fig. 1

Fig. 2

Fig. 3

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Ovalization of the roll

Roll centres damaged or bent.
Bad alignment of the centres.
Too much or too litle play between the centres and the rolls.
Angles different from the centres.
Centres of the machine in bad condition.
Badly driven roll.
Irregular cooling.
Concave rolls ( in case of long rolls)
Steadies not correctly positioned.
Cutting too deep.
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Fig. 4

Fig. 5

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5.4 Irregular surface finsh on the strip

ROLL TYPE
Work rolls
GRADE
All
DESCRIPTION
Irregular brilliance or colour on the strip.
POSSIBLE CAUSE(S)
Local variation of the roll hardness, which follows a rolling incident (fig.1) or a grinding mishap.
(fig.2).
Rupture of the oil film (whitish zones).
CORRECTIVE ACTIONS
Remove all the defects that were formed during the previous run.
Try a steel grade with more vanadium.
Change the mill parameters and/or the oil.

Fig. 1
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Fig. 2

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6. Formation mechanisms
6.1 Surface fatigue
FORMATION MECHANISM
During rolling, the maximum shearing stresses (Hertz theory) exceed the fatigue limit of the roll material
below the surface.
Cracks appear and develop under cyclic rolling stresses.
They reach the surface and form small splinters that tear out : the phenomenon is called spalling or
micro-spalling. The aspect of the rupture is unpolished as a result of the micro-movements of the metal
grains before they separate.
ORIGINS
Local : overpressure, indentation, slippage, excessive stresses, marks
Ex:
- Back up roller in contact with the 2nd intermediate drive roll.
- Junction zone of the cone with the barrel of 1st intermediate rolls.

General: runs too long, insufficient grinding

DETECTION
The surface fatigue comes generally with a deep work hardening that accumulates run after run,
and can locally reach 4 HRc (40 Ld) more than the original hardness.
ACTION
Grind until the roll original hardness is restored
CORRECTIVE ACTIONS
Measure the Equotip hardness Ld after grinding.
Measure by filiation every X campaigne (to be defined) the sensitive zones (ex. Cone junction) and
restore the hardness to the original value.

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6.2 Damage due to overheating

ASPECT
Cracks on the surface parallel and aligned (fig.1) or in network (mosaic, fig.2).
Disturbed hardness (lower or higher).
Micro-spalling.
FORMATION MECHANISM
High local rise in temperature, above that of the tempering (about 500C), even that of the hardening
(example: when sticking, some points exceed the fusion temperature). This leads to a modification of the
micro structure and the hardness and to unbalanced internal stresses.
Cracks are then produced by stress relaxation.
In case of successive insufficient elimination of these micro cracks, micro spallings propagate later on
under cyclic rolling stresses.
ORIGINS
Strip sticking.
Slippage between the rolls.
Blockage of the roller.
Grinding wheel shock.
Grinding parameters inadequate.
Rupture of the lubrication film.
DETECTION
Structure modification can be detected with an etching test.
Hardness disturbance: Equotip hardness filiations of the neighbouring areas.
Cracks: non destructive tests such as dye penetrant, magnetic, ultrasonic, Eddy current.
ACTIONS
Completely eliminate the faults by machining, then carry out a non destructive test.
See also the chapter on the effect of strip sticking.

Fig. 1, After dye penetration

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Fig. 2, After magnaflux

Fig. 3, After magnaflux

Fig. 4, After Nital etching

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Fig. 5, After etching dark zones heated above tempering temperature

Fig. 6, After etching in clear hardened zones heated above hardening temperature

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6.3 Consequenses of a rolling incident

SUBJECT
Work roll (12%Cr grade) after a sticking of stainless strip.
DESCRIPTION
The roll has small sections of folded strip stuck to the barrel (fig.1-2).
A sample is removed for a cross-examination of the effected zone (fig.3).
The macroscopic examination of the face, after polishing, shows a series of cracks, at regular
spaces, that go directly to the center of the sample (fig.4).
The microscopic examination gives a closer view of these cracks and distinguish 3 layers: A, B and
C (fig.5-6).
A : On the surface, the strip which has stuck approximately 0.15 mm deep.
B : a thermally effected zone presenting a modification of the structure and a 63 HRc
hardness. Depth : 0.2 mm.
C : a cracked zone corresponding to the original structure affected by a gradient of the
tempering temperature starting from the interface with zone B.
Depth approximately 1.5 mm. Original metal hardness 61 HRc.
FORMATION MECHANISM
The sticking of the strip to the barrel is accompanied with a high rise in temperature, locally higher
than that of the transformation points.
The reheat treatment, checked by a rise in hardness and the changing in structure, leads
simultaneously to the zone B being placed under compressive stresses and with the zone C, which
has been softened (tempering effect), cracking under tensile stresses
CONSEQUENCES
After this kind of incident, a light grinding eliminates all the sticking marks on the surface. If not eliminated
the underlying cracks will develop during the next runs and will mark the product, cause micro spallings
and even the rupture of the roll.
The illustrated case needed a 3 mm reduction of the diameter in order to assure the complete elimination
of the consequences of an incident of an average intensity.

Fig. 1 Work roll after incident

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Fig. 2 Sticking of a stainless strip

Fig. 3 Cutting of a sample in the affected area

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Fig. 4 10 X enlargement

Fig. 6 Micrography after Catella etching 100X

A= strip, B= overheated area, C= unaffected material

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