SCI Course Lecture-1

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
Rolling Mill Rolls are high-impact key assets

the work horses of any rolling mill
This lecture will highlight the importance & impact of rolls in multiple
aspects costs, product quality, process & daily operations, supply security
3
Lecture 1
Importance of Rolling Mill Rolls
Importance of Rolls
Harsh operating conditions
High total
cost of
ownership
Heart of
the rolling
process
Cooling/mill hardware &

scheduling requirements
Impact on
mill
operations,
downtime,
capacity,
capability
Impact on
product
quality
Roll failure
risk
Supply security
Ensure rolls are defectfree & fit-for-purpose
roll shop operations

transport, handling,
storage
roll inspection
Importance of rolls
Rolls: high-impact key assets for rolling mills
High costs
roll purchasing
roll shop
texturing, Cr-plating
mill downtime for roll
changes & failures
working capital tied up
in roll fleet
storage space
High impact on
product quality
High impact on
operational level
surface defects
rougness / texture
transfer
strip gauge & shape
rollability of product mix
mill scheduling /
planned roll changes
unplanned roll changes
safety aspects, roll
failures & prevention
mill pacing
mill vibrations, friction
cooling requirements
transport/handling
Supply security
lead times can be very
long & roll consumption
can fluctuate
mills require tailored
roll properties rather
than off-the-shelf
products from roll
suppliers
Roll use = core competency for Tata Steel rolling mills
Need for cooperation
cannot be left / outsourced successfully to third parties
with top quality roll suppliers
Rolls technology: Core area for Tata Steel mills and R&D
Rolls procurement: Strategic function with lead buyer for Tata Steel Group
Importance of rolls
High costs
roll purchasing
roll shop
changes & failures
in roll fleet
storage space
High impact on
product quality
High impact on
operational level
surface defects
rougness / texture
transfer
strip gauge & shape
mill scheduling /
mill pacing
transport/handling
Supply security
can fluctuate
than off-the-shelf
products from roll
suppliers
Financial impact of roll use in tandem cold strip mills
Roll costs per tonne - year 2003 .
pounds per tonne
10
8
6
Miscellaneous, chocks, ..
Roll stock costs
Mill downtime costs
Roll shop costs
Material costs
4
2
0
Port Talbot
Llanwern
CSPY- CM21
CPPIJmuidenCM11
CPPIJmuidenCM12
not included:
cost of roll-related coil rejections / repairs / downgrading
consequential damage of roll failures (other than loss of roll life)
roll purchasing costs of new rolls constitute only a minority fraction of the total costs of
roll usage (TCO = total cost of ownership).
Financial impact of roll use in HSMs

total roll-related costs in Corus Hot strip mills;
Mill downtime costs for roll changes
year=2004
total roll-related costs
18.000.000
16.000.000
Miscellaneous, chocks, ..
Roll stock costs
Roll shop costs
Roll material costs
roll-related costs per tonne
20.000.000
14.000.000
12.000.000
10.000.000
8.000.000
6.000.000
4.000.000
roll-related costs per tonne in Corus Hot strip mills;

year=2004
Mill downtime
costs for roll
changes
Miscellaneous,
chocks, ..
3
Roll stock
costs
2
Roll shop
costs
2.000.000
HSM
Port Talbot
roll material costs per km strip

in Corus Hot strip mills; year=2004
HSM
Llanwern
HSM
Port Talbot
HSM2
IJmuiden
roll material costs per tonne
Rear Finishing Mill

Work Rolls (EC/IC)
Early Finishing Mill
Work Rolls (HiCr/HSS)
Roughing Mill Work
Rolls
30
HSM2
IJmuiden
3,00
50
40
HSM
Llanwern
roll material costs per tonne

in Corus Hot strip mills; year=2004
Edger & HSB rolls

Back-up Rolls
roll material costs per km strip
Roll material
costs
20
10
2,50
2,00
Edger & HSB rolls

Back-up Rolls
Rear Finishing Mill Work Rolls (EC/IC)
Early Finishing Mill Work Rolls (HiCr/HSS)
Roughing Mill Work Rolls
1,50
1,00
0,50
0,00
HSM Port Talbot
HSM Llanwern
HSM2 IJmuiden
DSP
IJmuiden
HSM Port Talbot
HSM Llanwern
HSM2 IJmuiden
DSP
IJmuiden
Raw material price development
TSG-SDS raw material prices
80
Nickel
5.0
Molybdenum
Vanadium 4.5
Chrome
4.0
Steel Scrap
70
3.5
60
3.0
50
2.5
40
2.0
30
1.5
20
1.0
10
0.5
50
0.0
Nickel
Molybdenum
Vanadium
Chrome
Steel Scrap
350
300
price index
Ni, Mo, V prices in /kg
90
400
Cr, steel scrap prices in /kg
100
TSG-SDS raw material price indices

(April-2010 = 100)
250
200
150
100
10
dec-10
jun-10
dec-09
jun-09
dec-08
jun-08
dec-07
jun-07
dec-06
jun-06
dec-05
jun-05
dec-04
jun-04
dec-03
dec-10
jun-10
dec-09
jun-09
dec-08
jun-08
dec-07
jun-07
dec-06
jun-06
dec-05
jun-05
dec-04
jun-04
dec-03
Raw material price fluctuations large impact on roll prices
Rolls procurement in TSG (May 2011)
Spend: estimated at US$ 100 Million per annum on rolls in TSG

$3,100,000
$18,400,000
$20,800,000
$21,700,000
Tungsten carbide
discs
Asia
Static cast
rolls/sleeves
Europe
Spin cast work rolls

Forged work &
intermediate rolls
$22,600,000
$80,500,000
$35,500,000
Cast & forged backup rolls
Since May 2011:

Some decrease in roll spend (TSE: less roll consumption & destocking; raw material prices )
Forecast FY14, FY15: again around US$ 100 Million (with bigger share for TSL: more mill output)
Mills/works: > 50 mills/works across TSG using rolls
Items: > 1,000 different roll items across TSG
Delivery times: Ranging from 3 months for small rolls (mainly for long product mills) to
>3 years for large (back-up) rolls
11
Importance of rolls
High costs
roll purchasing
roll shop
changes & failures
in roll fleet
storage space
High impact on
product quality
High impact on
operational level
surface defects
rougness / texture
transfer
strip gauge & shape
mill scheduling /
mill pacing
transport/handling
Supply security
can fluctuate
than off-the-shelf
products from roll
suppliers
12
Supply security
Rolling mill rolls are not available of-the-shelf
Unique geometrical design
per mill and per roll type
Rolls tailor-made to customers order
Lead times can be very long
Variations in mill output, product mix,

rolling process, mill condition, excess
roll consumption
Fluctuating roll consumption rates
challenging task to ensure that:

mills will always have sufficient
rolls to keep on rolling
whilst avoiding excessive stock
Once, work rolls were transported

by airplane from Brazil (!) to
The Netherlands to prevent DSP
mill stoppage due to lack of rolls
13
Supply security tailored rolls

mill-specific roll requirements (microstructural) material properties
A successful roll grade in a certain mill may perform poorly or even fail in a different
rolling application
standard roll grades offered by suppliers still need to be fine-tuned
especially for more demanding rolling applications
Maintain fruitful bilateral relations with several key roll suppliers

ensure an adequate level of technology exchange
roll supplier needs to know the mill and grasp its key requirements
roll user should understand the capabilities and limitations of the roll manufacturer
14
Importance of rolls
High costs
roll purchasing
roll shop
changes & failures
in roll fleet
storage space
High impact on
product quality
High impact on
operational level
surface defects
rougness / texture
transfer
strip gauge & shape
mill scheduling /
mill pacing
transport/handling
Supply security
can fluctuate
than off-the-shelf
products from roll
suppliers
15
High impact of Rolls on product quality

(1) Gauge & shape
Rolls are the work horses of any rolling mill
The tool to deform slab, bar or strip
dimensions required for the customer or for downstream operations.
Gauge & shape control within tight tolerances

roll wear (work rolls, intermediate rolls, back-up rolls) has to be sufficiently low and
homogeneous
Work roll change build-up of thermal crown thermal properties of roll

important
Cold rolling: rapid build-up of a stable thermal crown required to limit length of out-of-
tolerance strip.
Hot rolling: shape actuators must be able to compensate for thermal crown
16

(2) Surface properties
Work rolls critical influence on surface
properties of rolled steel product
transfer of roughness / texture to the strip surface

visual appearance
processability in downstream/customer operations,
coating thickness requirements
Trend: customer expectations requirements

regarding strip surface roughness / texture
E.g. automotive market: narrow Ra range combined with
high Peak Count (>75
cm-1
Tata Safari
at bandwidth 1 m)
Rollrelated surface defects due to

roll marks
excessive roll wear
premature work roll surface degradation
17

(3) Tribological aspects
Work rolls = key component in tribosystem:

strip work roll lubricant (if any) process/loads
strip and the work roll may be coated. This coating may also be an oxide layer.
Lubricant may also be water
Tribo-system governs important parameters such as strip cleanliness and friction

level in the mill requires insight in role & properties of work rolls.
Some Cold Mills are using Cr-plated work rolls to avoid poor strip cleanliness
Cr-plating from Cr(VI) SHE issue restrictive EU legislation need for alternatives
DSP IJmuiden cannot use certain HSS rolls due to high friction/mill vibrations
Friction level roll properties

mill force and power requirements
product rollability limits for a mill (grade/gauge/width-combinations)
Roll design limits can be more restrictive for product rollability than mill power
18
Importance of rolls
High costs
roll purchasing
roll shop
changes & failures
in roll fleet
storage space
High impact on
product quality
High impact on
operational level
surface defects
rougness / texture
transfer
strip gauge & shape
mill scheduling /
mill pacing
transport/handling
Supply security
can fluctuate
than off-the-shelf
products from roll
suppliers
19
High impact of Rolls on operational level

(1) scheduled roll changes
Mill operations generally scheduled into rolling campaigns
work roll changes scheduled before each new campaign
maximum # coils & sequence of coils to be rolled within a campaign are strongly determined by the behaviour,
capabilities and limitations of the work rolls
some mills: different campaign types with different work roll requirements
ground cambers
surface finish
Work rolls determining factor for mill logistics
Work roll changes = daily routine at mills
frequencies up to several times per shift depending on the mill type and campaign type
Trend in certain markets customers requesting smaller orders with shorter lead times
some mills confronted with shorter average campaign length roll change frequency
due to logistical constraints regarding the coil sequence in a campaign
Aspirational target: Schedule-free rolling
eliminate (majority of) planned work roll changes
allow maximum scheduling freedom
Mills will generally not be able to implement schedule-free rolling with current roll fleet development,
trialling and implementation of new work roll types
20

(2) unplanned roll changes
unplanned roll changes disturb the normal routine

disproportionally high effect on mill operations
Particularly in cases of roll failure / serious roll damage occurs
extensive mill downtime
effort to remove havoc & get mill ready for restart
Disturbance of upstream operations are also disturbed
E.g: roll failure in DSP / TSCR mill abortion of casting process; slabs in furnace scrapped
Special safety precautions required in cases of spallings or serious damage of a roll type
with high residual stresses
compressive stress levels 500 MPa at the hardened barrel surface
forged rolls
CPC-HSS rolls
21

(3) roll shop operations
Roll shop comprises large & vital part of operations associated with any rolling mill
Roll shop task: ensure that rolls are prepared correctly & in time for next rolling
campaign.
This includes:
Adequate redressing of the barrel surface

remove surface layers affected by wear, thermal fatigue and work hardening
Application of the correct ground profile and surface finish
Routine Non-Destructive Testing (NDT) of rolls before each new rolling campaign
shield the mill from potential harmful incidents caused by rolls with a defect or remnant damage
from a previous mill incidents
Perform/arrange roll repairs

salvaging of damaged rolls
arrange repair of rolls with worn journals
Mounting and dismounting of roll sets
(Re)chamfering barrel edges
Roll fleet management

22

(4) transport + handling
Frequent roll changes
Comprehensive (roll shop)

activities on each roll
extensive transport & handling operations associated with roll usage
inside roll shops as well as between the roll shop and the mill
Even more for some mills not located in same building as their roll shop
Sometimes routine transport of rolls via public motorways
Some roll shops are serving multiple mills
complex logistics, operations & roll fleet management

E.g: Cold Strip Mill IJmuiden roll shop, serving:
CM21, CM22, TM21, HDGLines#1,#2,#3 IJmuiden

Segal HDGLine in Lige
HDGLine in Moerdijk (JV Wupperman/Tata Steel)
BUR grinder also in use for other mills
M4 motorway between Llanwern

and Port Talbot (100 km)
23

(5) implications for mill hardware & process
Work roll cooling essential for all hot & cold rolling mill
Carefully designed cooling systems high, stable & homogeneous heat transfer
Optimum coolant flow rates are (a.o.) dependent on work roll properties & rolling speed
Inhomogeneous cooling can lead to
premature local roll surface degradation
strip surface defects
poor strip shape
rolling process instability
Roll cooling systems must also exhibit a very high reliability

complete roll cooling system failure (e.g. valve not opening)
or even partial roll cooling failure (e.g. blocked nozzles)
rapid catastrophic
roll failure
Hot rolling: additional strip surface cooling devices also required
interstand cooling, chilling/skin cooling headers (a.k.a. anti-peeling headers), edge spays
suppress formation of Fe2O3-rich oxide scale abrasive for work roll surface
diminish thermal degradation of the work roll barrel
avoid roll-in oxide defects on the strip surface.
Also in this respect, work roll properties are important, as they
influence the optimum strip cooling requirements, and

determine the resilience of the work rolls if the mill is operating outside the optimum window respect to strip
cooling/strip surface temperature
24

(7) friction, chattering, rolling loads limitations
Friction work roll properties
A change in work roll material properties can substantially affect the friction coefficient
E.g. HSMs experience: HiCr Iron work rolls HSS work rolls friction
Friction at mill campaign start behaviour of the roll in the grinding process
friction evolution during rolling campaign work roll surface evolution
In some mills, chattering (mill vibrations) is a serious problem
related to the previous topic friction and dependent on work roll properties
Roll material strength limits impose maxima to rolling loads
maximum allowable torque, bending

force, total and specific rolling forces,
rolling pressure, and Hertzian contact
stress.
installed mill power can exceed strength
limits of rolls.
6-high mill with IMR shifting
asymmetrical distribution of loads and
contact stresses can easily lead to
exceeding the rolls Hertzian stress limit.
changes in product mix and/or rolling
practice roll fleet still fit-for-purpose?
25
Roll change reasons Hot Strip Mills (2004)

HSM Port Talbot
0,06%
25%
0,01%
0,02%
0,06%
IRC - planned
0,4%
7%
End of programme (EOP)

EOP for logistics
0,04%
IRC - extra
0,08%
0,08%
68%
BUR change
Shape
Slip / skids / roughness deviation
0,03%
Vibrations / shudder
CSP-UK Hot Strip Mill Llanwern
Cobble
0,02%
Pinch / tail marks
0,48%
14,4%
Other roll marks / rolling incidents
Defect free or orange peel
Roll failure in mill (spall etc.)
Fire cracks
light banding
medium/heavy banding
Bearing failure
0,11%
1,5%
Firecracks
tail marks
heavy bruise
Other reasons
0,44%
Vibration/grinding lines
light comets
0,42%
medium/heavy comets
84,2%
CSPY - DSP
CSPY - HSM2
tail marks
6%
8%
0,3%
5%
medium/heavy
banding
9%
Other
30%
0,02%
5,2%
0,02%
0,25%
0,27%
8%
0,09%
0,6%
1,1%
80%
0,005%
Defect free
or orange peel
70%
light banding
7%
heavy bruise
0,1%
Vibration/
grinding lines
0,7%
light comets
4%
medium/heavy
comets
2%
Fire cracks
26
0,6%
Roll change reasons

Cold Mill 21 IJmuiden
discontinuous sheet mill
Other reasons
3%
CSPY - Cold Mill 21

reasons for work roll changes
2003
End of program / Tonnage
Shape
1%
Strip break
Weld break
Slip / skids
1%
Roughness
20%
Pinch
Burr marks
Too fast out ("uitloper")

1%
End of program / Tonnage

43%
1%
Lines / streaks
1%
Bruises / cracks
Other marks
(imprints/drag/pits/...)
Lines / streaks
Other marks
(imprints/drag/pits/...)
13%
Too fast out ("uitloper")

Slip / skids
Bruises / cracks
0%
Burr marks
3%
Roughness
Pinch
10%
Weld break
2%
Strip break
1%
Shape
Other reasons
27
Roll Property Requirements - summary

Roll Surface
Roll Core
Tensile strength
Torsional strength
Bending strength
Toughness
Ductility
Fatigue strength
Thermal shock resistance
Wear Resistance
Cold mills, temper mills: good roughness and texture
retention
Hot mills: abrasion resistance, thermal fatigue/
degradation resistance
Resistance to indentation / marks

Corrosion resistance / ability to form a stable thin
oxide layer (hot mills)
Resistance to bruising
Resistance to localised overheating
Resistance to spalling
Machinability/Grindability
Strip cleanliness not jeopardised
Roll total
Resistance to catastrophic fracture

Resistance to roll flattening
Fast build-up of steady-state thermal crown
Resistance to high contact pressures
Value-for-money
28
Balancing roll requirements
Seemingly conflicting roll requirements need to be reconciled;

roll properties need to be balanced for each application:
Roll barrel shell relatively hard; roll core&neck tough
Compressive stresses in hardened shell
tensile stresses underneath
Barrel hardness:
WR (temper mil) > WR (cold strip mill) > IMR > BUR
Use of Cr-plated work rolls:

to improve roughness/texture retention
particularly for temper mills, sometimes tandem mills
for certain cold rolling mills strip cleanliness is a motivation
expensive: not always cost-effective

Cr(VI) bath => SHE issue.
29
Work rolls:
Balance wear resistance and incident resistance
mill / stand mapping
10
roll mapping
20
old rolls generation
Mill 1
8
current rolls generation
16
Roll
type 1
incidents
incident resistance
Match mill & roll
12
wear
development
0
2
Roll type 2
Match mill & roll
Mill 2
0
future rolls generation
10
wear
4 resistance
6
10
30
Back-Up Rolls:
Cast versus Forged Back-Up Rolls
Primary concerns that affect BUR performance

Bruises / impressions
Wear
Rolling contact fatigue
Lightly loaded mills (e.g. temper mills, DCR mills):

cast iron back-up rolls
make use of low wear rates offered by these grades
Heavy mill loads

forged steel back-up rolls
refined grain structure; induced longitudinal grain flow
increased fatigue resistance / incident resistance
Cast steel back-up rolls: intermediate case.
31
Some typical roll chemistries
Cr
Ni
Mo
W / Nb
(%)
(%)
(%)
(%)
(%)
(%)
3 3.5
1.5 2.5
4-5
0.2 0.5
< 0.1
< 0.1
3 3.5
1.5 2.5
4-5
0.2 1
<1
< 1.5 Nb
Cast HiCr steel
1.5 - 2
11 - 14
0.5 1.5
2-4
0.2 - 1
0.21 W
Cast HiCr iron
2.8
17 - 19
0.5 1.5
0.5 2
< 0.1
< 0.1
Cast HSS
12
4-8
0.5 2
2-8
2-8
28W
standard forged steel
0.7 - 1.0
1.5 - 6
0.2 2
0.1 - 0.6
< 0.1
< 0.1
forged semi-HSS
0.5 - 1.0
4 - 10
1-2
0.5 - 2
0.5 - 1
<1W
Forged HSS
0.8 - 1.5
8 - 13
1-2
0.5 - 3
0.5 - 3
<2W
Grade
alloy indefinite chill (AIC) iron
(nickel grain iron)
Enhanced AIC
(super nickel grain iron)
Each rolling application requires tailored roll properties

Wide variety of roll manufacturing routes, chemistries, heat treatments, microstructures
32
Schematic of Static Single Pour and Static Double Pour

Techniques
Static Single
Pour Casting
Static Double Pour Casting

33
Schematic of Centrifugal Casting
Shell pouring
during fast
spinning
Shell
solidifies
Solidified shell
Core top poured

and spinning
decreased
34
Schematic manufacturing route for forged rolls
Hardening
ESR (electroslag refining)
35
Electroslag Refining (ESR)
Consumable
electrode
Benefits:
Molten
electroslag
Purification
Steel structure
Application of ESR:
Liquid
steel
Water
cooled
rising
mould
Solidified
refined
ingot
In case of high content of

alloying elements
In case of high surface quality
requirements (e.g. Al foil)
For deep hardened rolls
For roll conversion
36
Hardening and tempering
Elemental steps in hardening process:

Austenising
roll heated above -Fe/-Fe transition temperature
Quenching
water quench
cryogenic cooling
formation of Martensite & a small percentage of retained -Fe
roll shell is hard but brittle
Tempering
controlled softening; roll becomes less brittle
Differential hardening (neck isolated from barrel)
Hardening furnaces
classical furnace
static induction hardening
dynamic induction hardening (single or double frequency)
37
Hardness versus tempering temperature
Forged 5% Cr steel rolls
Vickers hardness
900
850
wear
resistance
800
incident
resistance
750
700
650
100
150
200
250
300
Tempering temperature (C)
350
400
38
Effect of a rolling incident on roll damage:

influence of the tempering temperature
rolling incidents induce a local
temperature peak
the lower the tempering temperature, the
more extended the zone where the
microstructure of the roll is affected.
39
Explosive failure risk of forged rolls
Explosion risk
Enormous compressive
stresses in shell
Compensated by enormous
tensile stresses internally
Internal stress levels up to 1000 MPa !!!

Crack in roll:
inherent explosion risk
Trend to roll life maximising
greater depth of hardening
better roughness retention => higher
hardness
more critical for explosion risk
40
Some trends in last decades
Hardening depth increase

roughly from 30 to 120 mm on diameter
i.e. roughly from 15 to 60 mm on radius
Higher barrel hardness

Higher metallurgical purity
Higher alloying content (2%Cr -> 3-8%Cr steel; HiCr iron)
Automated roll inspection
Development of induction hardening techniques
Micro-alloying with strong carbide formers (e.g. 4%Cr-Mo)
Macro-alloying: forged semi-HSS and HSS grades
41
Breakthrough Technology:
Development & testing of forged HSS rolls
most promising current direction for breakthrough roll technology for cold rolling
forged semi-HSS and most particularly forged HSS grades
Grade
C (%)
Cr (%)
Mo (%)
V (%)
W (%)
Standard Forged
0.7 - 1.0
1.5 - 6.0
0.1 - 0.6
< 0.1
< 0.1
Forged semi-HSS
0.5 - 1.0
4.0 - 10.0
0.5 2.0
0.5 1.0
< 1.0
Forged HSS
0.8 - 1.5
8.0 - 13.0
0.5 - 3.0
0.5 - 3.0
< 2.0
Approximate tangential
residual stress (MPa)
400
200
0
-200
50
100
150
200
250
-400
-600
-800
-1000
Forged HSS
Forged 5% Cr steel
-1200
Depth in radius (mm)
finely dispersed
hard carbides

enhanced wear resistance
high tempering temperature

(~ 480C) possible

enhanced incident resistance
Lower residual stress levels

elimination of explosive
failure risk
42

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R&D-PRC-SRC

Surface Conditioning & Interaction course

Surface Conditioning & Interaction course

A focus on rolling mill rolls within Tata Steel

Rolling Mill Rolls are high-impact key assets

Importance of Rolling Mill Rolls

Cooling/mill hardware &

roll shop operations

Roll use = core competency for Tata Steel rolling mills

Need for cooperation

cannot be left / outsourced successfully to third parties

with top quality roll suppliers

Roll use = core competency for Tata Steel rolling mills

Need for cooperation

cannot be left / outsourced successfully to third parties

with top quality roll suppliers

Financial impact of roll use in tandem cold strip mills

Roll costs per tonne - year 2003 .

pounds per tonne

Financial impact of roll use in HSMs

total roll-related costs

roll-related costs per tonne

roll-related costs per tonne in Corus Hot strip mills;

roll material costs per km strip

roll material costs per tonne

Rear Finishing Mill

roll material costs per tonne

Edger & HSB rolls

roll material costs per km strip

Edger & HSB rolls

HSM Port Talbot

HSM Port Talbot

Raw material price development

TSG-SDS raw material prices

Ni, Mo, V prices in /kg

Cr, steel scrap prices in /kg

TSG-SDS raw material price indices

Raw material price fluctuations large impact on roll prices

Rolls procurement in TSG (May 2011)

Spend: estimated at US$ 100 Million per annum on rolls in TSG

Spin cast work rolls

Cast & forged backup rolls

Since May 2011:

Mills/works: > 50 mills/works across TSG using rolls

Items: > 1,000 different roll items across TSG

Roll use = core competency for Tata Steel rolling mills

Need for cooperation

cannot be left / outsourced successfully to third parties

with top quality roll suppliers

Rolls tailor-made to customers order

Lead times can be very long

Variations in mill output, product mix,

Fluctuating roll consumption rates

challenging task to ensure that:

Once, work rolls were transported

Supply security tailored rolls

Maintain fruitful bilateral relations with several key roll suppliers

Roll use = core competency for Tata Steel rolling mills

Need for cooperation

cannot be left / outsourced successfully to third parties

with top quality roll suppliers

High impact of Rolls on product quality

Gauge & shape control within tight tolerances

Work roll change build-up of thermal crown thermal properties of roll

Friction level roll properties

friction evolution during rolling campaign work roll surface evolution