R&D-PRC-SRC

Surface Conditioning & Interaction course

Focus areas: Rolls, Defects & Inspection
Champion: Sudhansu Pathak
Lecturer: Dr Henk Bolt & Dr Lene Hviid
March 2013 - Jamshedpur

Surface Conditioning & Interaction course

Time schedule
Tuesday

5th of March

Wednesday

6th of March

Thursday

7th of March

9.00 to 10.30
Lec. 1
Importance
of Rolls

10.45 to
11.30
BREAK

9.00 to 10.30
Lec. 5
Quality
control
SDC

BREAK

10.45 to
11.30
BREAK

9.00 to 10.30
Two sessions
in plants
(choice)

Lec. 2
Performance
of rolls &
surface

11.30 to
12.45

Lec. 6
Surface
inspection
and control

1. Rolls
training
2. SIS
training

LUNCH

11.30 to
12.45
BREAK

10.45 to
11.30
BREAK

Lec. 3
Rolls failure
& Rolls
database

Lec. 7
Inspection &
Coilgrading

1. Rolls
training
2. SIS
training

Lec. 4
Lubrication

BREAK

15.00 to
16.00
LUNCH

11.30 to
12.45
BREAK

16.15 to
17.15

15.00 to
16.00

Lec. 8
A3 solving
method for
defects

Exercise
Rolls/lubric.
problem
16.15 to
17.15

BREAK

Exercise
customer
defect
complaint

15.00 to
16.00
LUNCH

1. Rolls
training
2. SIS
training

A focus on rolling mill rolls within Tata Steel

Take good care of Rolling Mill Rolls Quality & Condition

to ensure safe & smooth rolling
This lecture will highlight roll failure analyses, mechanisms and 3
prevention in development: TSG-wide roll defects & failures expert system

Lecture 3

Rolling Failures & Roll Failure Prevention

expert system development for rolls defects & failures

Topic No. 1: Safety

Safety in roll usage =
priority no. 1 !!!
400
200

Approximate tangential
residual stress (MPa)

General risk of handling heavy items

Specific risk:
 catastrophic roll spalling

0
-200

50

100

150

200

250

-400
-600
-800
-1000

Typical stress distribution in

forged 5%Cr steel work roll

-1200

Depth in radius (mm)

Forged rolls: very high internal stress levels

up to 1000 MPa

Large amount of energy stored in roll

Defect in roll:
 Sudden energy release can occur in violent way
 Inherent explosion risk

Also CPC-HSS rolls are high-stress rolls

>500 MPa

Risk analysis

Risk = (probability) * (effect)

Risk of personal injuries due to roll failures =

(probability of a roll failure) *
(probability of someone being struck) *
(effect of flying roll piece on person)

Probability of a Roll Failure

Any defect origin could create an explosion risk:

defect origin

manufacturing
flaw

Rollmakers:
- Roll quality !
- Trend:
quality  versus
requirements 

rolling incident
instantaneous damage

Roll users:
- Rolling mill
process stability
- Incoming HR strip
quality

fatigue; undiscovered /
insufficiently removed
damage from
previous incident
Roll users:
- adequate roll change,
redress, NDT scan
routines
NDT specialists:
- NDT hardware
& expertise
7

Instantaneous roll failures

moment & location
of a roll failure
instantaneous
failure in mill stand
during rolling
Immediate risk
very low

Catastrophic effect of rather heavy cold rolling process incident

on conventional forged 5%Cr steel work rolls
Strip derailment at full speed
Immediately followed by roll spalling in mill stand

Probability of person being struck

by roll piece
moment & location
of a roll failure
instantaneous
failure in mill stand
during rolling

(minutes, hours, days)

Immediate risk
very low

Comprehensive mill &

roll shop procedures

Rare but
most dangerous

- suspect rolls:
quarantine
- covers
- handling
-

- Early defect detection

& adequate removal

- Stress relieve
may be incomplete
- Knock-on damaging
of other rolls in mill

delayed failure
after mill incident

unexpected failure
outside mill

- Reduce explosive nature

of roll spalling
9

Partially spalled rolls can still be

dangerous !

Fatigue path hidden by a bridge

surrounded longitudinally by two
cone shaped-spalls.
Large stresses still present

Fatigue path evident on the fracture

face after removal of the bridge.
Stresses relieved
10

Dye Penetrant Testing

(DPT)

Roll inspection
Hardness Testing

(by rollmaker)

Equotip (LD, LE)

Shore-C, Shore-D

Vickers (HV)
Rockwell-C

Manual NDT methods

Visual Testing (VT)
Dye Penetrant Testing (DPT)
Magnetic Particle Testing (MPT)
Etch testing (3 - 20% nital)
Manual Ultrasound Testing (UT)
Acoustic Emission (AE)

Nital-etched roll surface

Evidence of bruising.
Note the presence of longitudinal
fire cracks within the bruise

NDT methods for automatic roll inspection systems

Automated Eddy Current Testing (ET)
Automated Ultrasound Testing (UT)
Electro Magnetic Acoustic Testing (EMAT)

Surface crack made

visible with MPT

11

Hardness testing
Check for:
Work hardening (particularly back-up rolls !)
Softening
Hardness drop during roll life
Hardness heterogeneities

Small BUR barrel spalling

due to work hardening

Equotip
hardness
test being
performed
on a roll
barrel

12

Eddy Current Testing (ET) - Principle

Coil's
magnetic field

Coil

eddy current
disturbance:
sudden => crack
gradual => bruise

Eddy current's
magnetic field
Conductive
material
(e.g. roll)
Eddy currents

13

ET roll inspection
Advantages

Disadvantages

+ easy to automate
+ bruise detection
+ sensitive

- only surface defects

- no clear relation between ET signal and
defect size/defect harmfulness
 tight cracks / electrical bridging cracks
- magnetism interferes with ET signal

Since its introduction in

the 80-s, routine ET
inspection in roll shops
has greatly contributed
to the reduction of roll
spallings and increased
roll performance

Cracks

Bruises

14

Ultrasound Testing (UT) Principle

High frequency sound waves are introduced into a material and they are
reflected back from surfaces or flaws.
Reflected sound energy is displayed versus time, and inspector can
visualize a cross section of the specimen showing the depth of features
that reflect sound.
initial
pulse

crack
echo

back
surface
echo

crack
0

10

plate

Oscilloscope, or flaw detector screen

15

UT roll inspection
Advantages

Disadvantages

+ versatile
+ detects deep-seated defects
+ sensitive
+ defect sizing & depth (tof)

- coupling required
- complicated, and sensitive to dirt
- not sensitive for bruises
- defect orientation affects detectability
- dead zone

Wave types
- Straight beam waves: 0 longitudinal
0.5-1 MHz for deep / through roll inspection
~ 2 MHz for standard applications
up to 10 MHz for sub-surface defect detection
manual and automatic UT systems in roll shops

- Shear waves: 45/60/70 transversal (angle beam)

- Several types of surface acoustic waves (SAW): 90

US2 depth

Sensitive to (sub-)surface defects 5 mm depth

Surface waves, longitudinal
Rayleigh surface waves, transversal
Creep surface waves, longitudinal
Manual probes require skilled operators
CM2 IJmuiden has 2 novel automated SAW+UT(0)+ECT combi systems

16

Topic No. 2: Incident resistance

Incident resistance in general very important
Even without safety aspect
Strip breaks, pinches, strip derailments, also minor incidents
 Mill incidents
excess roll stock loss
often >50% of total work roll consumption in tandem mills
scrap, salvaging, extra grinding
 Roll shop effort
 Impact on daily mill operations (roll changes)
Tolerance for mill incidents
key requirement for tandem mill rolls
Ideal roll: not affected by any incident
2nd best solution:
no effect of minor incident;
minimal redress after big incident
slow crack propagation
17

3%Cr steel work roll no. 687390

typical damage after medium-heavy strip break

strip scrap

optical
micrograph
nital-etched
sample

strip scrap
adhering to roll

work roll
200 m

Hardness-vs-depth curve
in damaged work roll

thermal
cracking

6 mm on radius
18

Incident/thermal impact resistance:

result of required grade & heat treatment
Forged rolls in cold mills

Cast rolls (e.g. in hot strip mills)

High barrel hardness required

Low tempering temperature = key limiting
factor for incident resistance
Conventional forged roll grades: trade-off

Incident
resistance

Maximum achievable barrel hardness lower

Roll mark resistance and strip cleanliness less
critical than in cold mills
Higher alloying
wear resistance
High tempering temperature
thermal impact
resistance

wear resistance &

anti-roll mark properties

HSS, semi-HSS, HiCr steel (HiCr iron):

high-T austenitising
+ multiple temperings
~1000C
Heat treatment for (enhanced)
ICDP, (S)NG, (HiCr iron):
only double/triple tempering

Forged 5%Cr steel rolls

850

wear
resistance

800

temperature

Vickers hardness

900

incident
resistance

750
700

~550C
~500C

650

100

150

200
250
300
350
Tempering temperature (C)

400
0
0

Other heat treatment key aspects:

temperature homogeneity over roll barrel
T-t combinations adequate for
retained austenite transformation
residual stress decrease

time

Effect of poor heat treatment:

HiCr steel roll barrel surface with
non-uniform hardness showing
premature thermal degradation

19

Rail Failure analysis example: spalling of cold mill work

roll 687463 - roll history (1)
5-stand tandem batch cold mill CM21 IJmuiden, 29 April 2006
Tail pinch
work roll 687-463 in stand #1 damaged.
Roll immediately changed and placed for 48 hours in quarantine (bomhok).

4 May 2006
First grinding pass, followed by first UT/ET scan
ET: Bruise and Crack indications detected.
UT: no subsurface (>2 mm depth) indications
cracks

bruises

20

Failure of work roll 687463: roll history (2)

cracks

4 May - 24 July 2006

Multiple grinding passes. Total stock
removal 1,61 mm (on )
Bruise & Crack signals now below
threshold
roll released.
Max. Bruise value =0.53 V. i.e still quite
significant.

bruises

25 July 2006, 22:45 h: Work roll 687-463 inserted into stand #2 top side.
26 July 2006, 2:30 h:
After rolling 990 tonnes, work roll 687-463 suddenly spalls during strip acceleration.
Spalled roll piece disrupts the rolling process
 strip break between stands #2 & #3.
 havoc; all 10 work rolls damaged; also back-up rolls in stand #2.
 Mill down for 4 hours to clean up; all damaged rolls in quarantine (bomhok)
21

Failure of work roll 687463:

Inspection of spalled work roll (1)
9 August 2006
Inspection of spalled work roll
Fatigue pattern observed
(ribbon fatigue spall or cat tongue).

22

Ribbon fatigue spalling

1 2
3
4

Crack propagation direction is

opposite to the revolution direction
of the roll
23

Failure of work roll 687463:

Inspection of spalled work roll (2)
9 August 2006 (continued)
Initiation point localised:
crack.
Location coincides with old
bruise indication.
Fatigue path spirals about
1 times around the roll
Spalling was just a matter
of time.

24

Learnings from failure of work roll 687463:

Measures in roll shop
Any damage inflicted to a roll during a heavy rolling process incident has to be
removed completely before the roll can be released for production again.
Partial damage removal by grinding until ET indications are reduced (just) under
threshold is no option any more.
Incident = each operation, manoeuvre or
set of circumstances by which damage is
inflicted to the roll surface. E.g.:
Pinches
Strip derailments
Strip breaks
Unlucky crane manoeuvres

# of rolls per
quarter

3
2

Damages:
visual damages
invisible damages: ET bruise & crack indications;
UT indications

New roll shop practice implemented at

CM2 IJmuiden

5-stand sheet mill

catastrophic work roll failures per quarter
due to fatigue crack propagation

improved procedure
1
0
year year year Q1 - Q2 - Q3 - Q4 - Q1 - Q2 - Q3 - Q4 - 2009+
Q1 2004 2005 2006 2007 2007 2007 2007 2008 2008 2008 2008 2010
2009

mill crew error:

roll pair not
changed after
rolling incident
25

New roll redressing and release procedure at

implemented at CM2 IJmuiden by 2006-Q4
Normal reason

Incident reason

Roll change reason given by mill

Yes

Roll goes for normal grinding

procedure followed by a Lismar scan

Roll salvaging

Is roll salvaging
needed?

Extra take off (maximum 0.6 mm)

No
Roll goes for grinding/scanning
procedure followed by Lismar scan

Yes

No
Yes
Bruise > 0,8 or
Crack > 0,5

Yes

UT1 > 35% or

UT2 > 35%
No

No
No

Bruise < 0,5 and

Crack < 0,3
Yes

Roll attended for

Roll manager

Bruise < 0,3 and

Crack < 0,2

No

Yes
No

Roll goes for final grinding procedure to

meet the customer demands
(roughness and crown)

Roll is destined
for circulation
Yes

Positive release of the

roll for production

26

Extra take off (maximum 1.5 mm)

UT1 > 35% or

UT2 > 35%

Roll failure causes overview

Roll failure analyses
Last 8 years: >100 individual industrial cases of roll failures/damage/defects
 at Tata Steel cold rolling mills in IJmuiden, South-Wales and India
In-depth analysis of certain selected cases

Reasons for catastrophic roll failures

A. Fatigue crack propagation (ribbon fatigue path or cat tongue)

 most common catastrophic work roll failure type
 origin = pre-existing defect (e.g. crack) at roll surface, from earlier mill incident,
propagating under rolling load

27

Roll failure analyses

Reasons for catastrophic roll failures in cold rolling mills

A. Fatigue crack propagation (ribbon fatigue path or cat tongue)

 most common catastrophic work roll failure type
 origin = pre-existing defect (e.g. crack) at roll surface, from earlier mill incident,
propagating under rolling load

B. Spalling due to instantaneous thermal and/or mechanical overload

 Origin = heavy mill incident (pinch, strip break, strip derailment, )

28

Roll failure analyses

Reasons for catastrophic roll failures in cold rolling mills

A. Fatigue crack propagation (ribbon fatigue path or cat tongue)

 most common catastrophic work roll failure type
 origin = pre-existing defect (e.g. crack) at roll surface, from earlier mill incident,
propagating under rolling load

B. Spalling due to instantaneous thermal and/or mechanical overload

 Origin = heavy mill incident (pinch, strip break, strip derailment, )

C. Roll manufacturing defects

 Frequent 30 years ago but nowadays rare
 E.g: deep-seated inclusions, hydrogen, too much (>10%) retained autenite
 Such incidents tend to be severe

Countermeasures

A.
Main focus in failure prevention at mills/roll shops

B.
Additional focus for development of incident-resistant roll grades
C.
Strict QA at rollmaker; optionally routine Ultrasound inspection at roll shops
29

Scenarios leading to fatigue crack propagation (A)

A1. Roll damaged in mill incident
roll not changed

fatigue crack growth
roll spalling in same rolling campaign

A2. Roll damaged in mill incident
roll changed

redressing in roll shop insufficient; remnant crack/bruise

roll back to mill
fatigue crack growth
roll spalling

A3. Combination of A1+ A2

Roll damaged in mill incident
roll not changed

fatigue crack growth but not up to spalling
regular roll change

redressing in roll shop insufficient; remnant crack/bruise

roll back to mill
fatigue crack growth
roll spalling

30

Example of scenario A3
Case: crack in forged 3%Cr steel work roll 687365
remarkably low Eddy Current Testing (ECT) signal
why ?
Finally intercepted by straight beam UltraSound Testing (UST) probe
installed by Lismar on grinding machine in parallel
with ECT

25 m

10 mm

Cross section of crack

Crack ragged, side-branched, discontinuous

electrical bridging

31
low ECT response

Roll failure analysis example: spalling of

work roll 687539
Incident description
5-stand tandem batch cold mill CM21 IJmuiden, 1 May 2006
18:05 hours: Heavy pinch of strip tail end in stand #1.
10 coils left in campaign, operator chose to continue without roll change.

Inspection of strip at stand #5 exit showed no marks

18:27 hours: with 3 metres left in the 4th coil after the pinch, the top roll no.
687539 exploded.
Top roll 687539:

Many fire cracks

multiple fatigue paths underneath

Bottom roll 687540:

Fire cracks up to 6 mm depth

no fatigue paths

Increase in stand #1 roll

force during pinch

High local pressure
& friction
32

Spalling of work roll 687539: images and

learnings

Spalled roll piece

Learnings:
recovered strip from pinch

strip inspection for roll mark defects is not

sufficient
rolls must be changed in each
case of (suspected) damage
Time between defect origin and spalling by
fatigue crack propagation can be very short (4
coils in this case)
Difficult to predict how fast (bottom roll had
similar cracks but no propagation observed yet
33

Roll defect analysis example: Cracks on

CM11 work rolls 556288 and 556292
12 January 2008, 4-stand batch tandem mill for tinplate CM11, stand #3

Work rolls 556292 (top) and 556288 (bottom), grade = forged 4%Cr-Mo steel, were
removed from CM11 stand #3, because imprints had been discovered on the strip.

Directly after pulling the roll pair, an area (30x30 mm) with several cracks, responsible for
the imprints on the strip, was indeed readily discovered on the surface of bottom work roll
566288.

34

Cracks on CM11 work rolls 556288 and 556292

Visual inspection of partner roll 566292
no cracks noticed
manual UST:

presence of cracks also on roll 556292, but cracks smaller than on roll 556288 surface
Roll 556292: cracks ~4 mm deep
Roll 556288: cracks 3-6 mm deep, except one 14 mm deep crack starting to bend

early stage of crack propgation

35

Cracks on CM11 work rolls 556288 and

556292 roll shop history review
Critical review of roll grinding and Eddy Current Testing History

Conclusion: rolls were sent to mill in defect-free condition

ECT after cracks were found

Strong coincident Crack/Bruise indications in roll 556288, weaker but clear coincident
Crack/Bruise indications

cracks

cracks

bruises

bruises

36

Cracks on CM11 work rolls 556288 and 556292

mill campaign review
Review of last mill campaign:

Only 3 coils rolled before roll pair was pulled

Anomaly: fast stop during rolling of 1st coil
Deceleration of stand #4 in 2.0 seconds,
stands #1, #2, #3 in 1.2 seconds

asynchronous
slip
friction

overheating of stand #3 work roll surface
Mill operator happy that strip break was
avoided during fast stop
rolling continued

2.0 seconds

stands
#1 #2 #3
roll speeds

stand #4
roll speed

In hindsight fast stop generated roll surface overheating (bruising)

crack initiation

Learnings:

Damaging effect of this particular fast stop on the work rolls has been understimated.
Anticipate that a fast stop from run speed may generate significant damage to the work
rolls, even if a strip break has been avoided
Cracks in roll had 556292 had not caused marked on strips (in contrast to cracks on roll
556292)
 Inspection of the strip surface for roll marks is pertinently insufficient to intercept all work rolls that

contain one or more cracks.

37

Lismars Prototype NDT system with novel

sensors tested in roll shop at Tata IJmuiden
Prototype system with a.o. novel automated UT-SAW sensors
Better defect detection capability

After successful trial: 2 grinding machines equipped with SAW

systems in combination with ECT + normal beam UST
UT-SAW now integrated in standard roll shop operations !!!
Example case: two small cracks in forged 3%Cr steel work roll

Automated routine NDT of rolls in roll shops:

added value of complementing Eddy Current Testing with Ultrasound Testing
straight beam & novel surface wave UST system

38

Examples of successful interception of defect

roll by means of Ultrasound Testing
Forged work roll 687 341:
multiple UST indications
1 campaign after rehardening at supplier

Cause: manufacturing problem (heat treatment)

only becoming manifest after mill load

Forged back-up roll 187 209

Cluster of UST indications due to inclusions

Cause: manufacturing problem (ingot casting)

only becoming detectable halfway roll life

39

Roll Failure Case Analysis approach

Roll Failure/Defect Case Analysis Elements
A. Check Roll/Roll Shop history data
roll shop cause?
 In particular Eddy Current Scans and Ultrasound Testing data
 Review data from previous mill/roll shop cycles: previous roll change reasons, extra
redressing required on lathe or grinder, successive ECT/UST C-Scans

B. Check Mill process data
mill cause?






High time-resolution mill proces data recorded just before & during roll failure
Rolling forces (total+differential), torque/power, tensions, speeds, screw positions,
Any abnormalities recorded earlier in same campaign?
Check roll cooling system data: (mal)functioning? On specification?

C. Check failed roll itself
indications for manufacturing defect or mill-induced defect or
mechanical damage or .?
visually
ultrasound inspection; other manual NDT methods
if relevant: local hardness measurements (portable Equoptip HLE or HLD)
If relevant: ambulant microscopy or sampling for chemical and microscopic analysis
 It is only sensible to take samples if the relevant sampling location is known

D. Check other involved rolls when applicable
circumstantial evidence & effects
 (Partner) work roll, Back-up roll/IMR

E. Check strip(s) for defects/marks when applicable
time & nature of origin
 Strip rolled during failure/defect recognition as well as previous strips

40

Example roll failure analysis:

Spalling of work roll 556254 in
stand #2 of Cold Mill 11

Roll examination

Roll shop data

Strip break in previous campaign,

followed by grinding off 0.24 mm
Eddy Current Scans OK
No sign of roll shop cause

Mill process data

Process data from last campaign,
recorded at high time-resolution, have
been checked thoroughly
No process irregularities have occurred
that could have induced a roll spalling

41

Manual Ultrasound Testing results

(normal beam + Surface Wave)
Large number of internal irregularities all along the roll length and circumference were found.
The defects are deep seated, from ~50 mm depth to the roll centre
Several deep-seated defects are already visible with a 2 MHz probe, if the applied ultrasound
measuring sensitivity is sufficiently large (i.e. 100% intensity of the 2nd back wall echo). This
indicates that the largest defects are at least 1.5 mm in size.
The number of ultrasound reflections increases considerably when applying a 6 MHz probe,
which implies that there is also a large fraction of defects in the size range between 0.5 and
1.5 mm.
These detected deep-seated defects are obviously roll manufacturing defects. They could be
either inclusions (e.g. slag) or gas bubbles (e.g. hydrogen). The ultrasonic-method alone can
not identify the specific nature of these inhomogeneities.
In the exposed zone of the fracture, it is evident that a concentrically fractured area was
developed from internally in the roll, as part of it was exposed when spalled. The green arrows
indicate the direction of the centre of that fracture. The area with the large green arrows is the
deepest part of the exposed part of the spalling, at about 50 mm below the original roll surface.
The area in the vicinity of the fracture was also analysed with ultrasound and it is found that
the crack only covers an equivalent circle, meaning that there is no unidirectional fatigue path
along the circumference (cat tongue), but rather an oval-shaped fish eye. The fracture of this
42
roll was most likely originated from one of the larger imperfections in the roll material.

Conclusions work roll spalling case of roll 556254

Roll 556254 spalled because of internal defects in the roll material.

With ultrasound testing it was detected that the roll has numerous deepseated internal imperfections, most probably either inclusions or gas
bubbles.
A significant amount of the defects is quite large (1.5 mm or more), while a
major portion of the defects has a size in the range of 0.5 to 1.5 mm.
This roll shop used only automated ECT. With additional UST the spalling
could have been prevented

Textbook example:
roll spalling due to a
deep-seated defect
43

In development:
Global Expert System
Rolling Mill Roll Defects and Failures
Why - How - What
Charter
Example pages

Global Expert System:

Rolling Mill Roll Defects and Failures
1.Why
Robust and safe rolling
processes and roll handling
operations require failure-free
rolling mill rolls and adequate
detection of and
responsiveness to any roll
damages and roll defects.

normal beam UT scan

2. How
A global web-based platform is created for TSG-wide knowledge
sharing and development concerning rolling mill roll defects and roll
failures. In this expert system, relevant data, characteristics, root
causes and countermeasures of actual cases of roll failures/defects
from any TSG (flat) rolling mill are centrally and collected and stored
in a systematic way.
The expert system is integrated and maintained within the TSG Hot
Rolling and Cold Rolling Process Improvement Teams (PITs) for
empowerment of the roll users by the roll users.

3. What
User-friendly web application containing:
Photos, roll data and mill data per roll
failure/defect
Breakdown of roll failure/damage modes
Breakdown of roll defect types
Breakdown per roll type/mill type
Breakdown of root causes
Description of prevention methods
This will be the backbone of the Expert
system to click-through site from
known symptoms to possible causes
and solutions
Discussion board
Links to relevant literature, functional and
technical documents
System controlled by roll users (one expert
per location/mill) modular and modifiable
45

Charter

Global Expert System: Rolling Mill Roll Defects and Failures

Objectives
Ensure robust and safe rolling processes and roll handling
operations by failure-free rolling mill rolls and by adequate
detection of and responsiveness to any roll damages and
roll defects:
Global knowledge sharing and development,
regarding rolling mill roll defects and failures.
Centrally collect and store data concerning rolling
mill roll defects and roll failures
Ensure open reliable and unambiguous data;
Clear descriptions with example photos of roll
defect/failure modes, root causes and
countermeasures
Controlled process/data approved by roll users

Deliverables

Benefits

User-friendly web application containing:

Photos, roll data and mill data per roll
failure/defect
Breakdown of roll failure/damage modes and roll
defect types
Breakdown per roll type/mill type
Breakdown of root causes
Description of prevention methods
Expert system click-through site from known
symptoms to possible causes and solutions
Discussion board
Links to relevent literature
Links to relevant functional and technical documents

Cross-border learning and sharing

Roll handling synergy
Less roll failures/damages
Faster & adequate response to incidents
High quality input - input must be complete Always up to date data set
System controlled by roll user modular and
modifiable
Data is centrally stored in a controlled ( and backupped) environment
Improved safety
Higher process stability/less downtime
Less emotional burden for operators

Scope
All roll types for flat rolling mills:
 hot strip mills, cold rolling mills, temper mills;
 work rolls, back-up rolls, intermediate rolls.
Opportunity to include in the future: rolls for long
products rolling

Identify

Share

Global
Expert
System

Critical Success Factors

Available manpower (R&D and GIS) (site
development
Absorption by PIT groups (future)
Each plant will have a nominated local expert to
maintain and develop site content (future)

Learn

Key activities

Action Timeline

Data Collection - identify and gather updateable

database of roll defect and failure information
Data Collation - categorize defect and failures in
appropriate groupings
Roll-out via PIT platforms
Introduction at surface day 2012?

Requirements gathering
Development of web-based tool
Testing
Deployment
Inform customers/users
Charter Global Expert System: Roll Defects & Failures

46

1. Roll Breakages
1.1. Roll barrel breakage

Description:

A roll barrel breakage constitutes the catastrophic failure of a roll in which the roll
fractures into 2 or more pieces through the complete roll barrel diameter

Causes:
1.1.a - Porosity (references.)
1.1.b - Poor roll core (references..)
1.1.c - Too thick shell (references.)
1.1.d - Centre bore defects (references.)
1.1 e Roll cooling failure (references.)

Countermeasures:

Most roll breakages are caused by manufacturing flaws; however, roll breakages are
also generally a consequence of a smaller defect which has either gone un-noticed or
not been correctly removed. Therefore, correct and timely non-destructive testing (NDT)
of the rolls will not prevent the defect from occurring, but will, in most instances, prevent
a suspicious roll from entering service.
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1.1. Roll barrel breakage

1.1.a Porosity

Porosity is characterised by hole defects that can appear on the surface, or subsurface
of a roll. The holes can be circular or irregular in outline and with or without a shiny
interior. They are randomly dispersed on the roll barrel of chill cast rolls. A prime example
of this defect type was found in 4.5%Cr cast steel back-up rolls (RS 154449)

This particular defect type is considered a manufacturing flaw and is predominantly found
in cast rolls
RefS. 154449 DSP-IJBR3223 static cast BUR 4.5%Cr double poured barrel breakage internal porosity supplier no.1

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