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

Lecture 2

Performance of Rolls
& Roll surface degradation

What is roll performance ?

Commonly used Roll Performance indicators:
tonnes/mm
km/mm

Amount of product
rolled per millimetre
roll consumption

~ 1/x
mm/kilotonne
mm/1000 km

~ $/mm
~ /mm
~ INR/mm
$/kT, /kT,
INR/kT

Amount of mm roll
consumption per unit
(tonnage/meterage) of
rolled strip

Amount of mm roll
consumption per unit
(tonnage/meterage) of
rolled strip

Focusing on
roll material
consumption
rate

Excluding/incidents:
roll wear/surface deterioration
vs resilience to incidents
(Ab)normal stock loss ratio
also depending on
mill condition and layout
difficulty of product mix
roll shop operations

Focusing on
roll material
costs

Roll costs per tonne - year 2003 .

Roll material costs is minority of

total roll-related costs!
Better Roll KPIs:
Total cost of ownership (TCO)
Value-in-use

More complex

Factors specific per mill / product

pounds per tonne

Better KPIs:
TCO and Value-in-Use

10
8
6

Miscellaneous, chocks, ..
Roll stock costs
Mill downtime costs
Roll shop costs
Material costs

4
2
0
Port Talbot

Llanwern

not included:

CSPY- CM21

CPPIJmuidenCM11

CPPIJmuidenCM12

cost of roll-related coil rejections / repairs / downgrading

consequential damage of roll failures

Examples:
PLTCM JSR: Anti-roll mark work roll properties = major
requirement (full-finish product requirement)
DSP IJmuiden: work rolls with low roll bite friction in
stands R2, F1 more important than roll consumption rate
Lower-stress forged HSS work rolls are expensive but not
susceptible to explosive failures  safety improvement
5

Example Roll performance data: TSE HSMs, 2005

tonnes rolled per mm roll

tonnes/mm, including incidents

tonnes/mm, excluding incidents
km/mm, including incidents
km/mm, excluding incidents

18000
16000
14000

1000
900
800
700

12000

600

10000

500

8000

400

6000

300

4000

200

2000

100

0
Port
Talbot /
F1-F4:
HSS

Port Llanwern HSM2-IJ DSP /

DSP /
Talbot / / F1-F3: / F1-F4: F2: HSS R2-F1:
F1-F4:
HSS
HiCr
HiCr
HiCr

Port Llanwern HSM2-IJ DSP /

Talbot / / F4-F7: / F5-F7: F3-F5:
F5-F7:
EC/IC
EC/IC
EC
EC/IC

HSS rolls: higher performance than HiCr iron and Indefinite Chill iron rolls
Including/excluding incidents can differ much
6
Comparison between mills difficult: mill layout & product mix factors

km strip rolled per mm roll

Finishing mill work rolls - 2005

20000

5000

R2

4000
trip length (tonnes)

HSM Roll
performance:
underlying factors

F4-F6

250

200

3000

150

2000

100
F7

1000

trip length (km)

average trip length in tonnes

average trip length in km
maximum trip length in km

Finishing mill work rolls - 2005

50

Campaign length
0

Finishing

1.4

Port
Port
Llanwern HSM2-IJ / DSP /
Talbot / Talbot / / F1-F3: F1-F4: F2: HSS
F1-F4:
HiCr
mill work
rollsF1-F4:
- 2005 HSS
HSS
HiCr

DSP /
R2-F1:
HiCr

Port
Llanwern HSM2-IJ / DSP /
Talbot / / F4-F7: F5-F7: F3-F5:
F5-F7:
EC/IC
EC/IC
EC
EC/IC

including incidents
average stock loss per trip (mm )

1.2

1.0

0.8

excluding incidents

Roll consumption
per mill campaign

Campaign length
affected by product
mix & scheduling

0.6

 affects mill output

& roll shop capacity
demand

0.4

0.2

 product quality
related

0.0
Port Talbot / Port Talbot / Llanw ern / HSM2-IJ /
F1-F4: HSS F1-F4: HiCr F1-F3: HSS F1-F4: HiCr

DSP / F2:
HSS

DSP / R2-F1: Port Talbot / Llanw ern / HSM2-IJ / DSP / F3-F5:

HiCr
F5-F7: EC/IC F4-F7: EC/IC F5-F7: EC/IC
EC

Rolls KPI Monitoring over time (TSG HSMs)

trends
opportunities
attention points
HSM Port Talbot HSS
HSM Port Talbot HiCr iron
HSM Jamshedpur HSS
HSM Jamshedpur HiCr iron
HSM Llanwern HSS
HSM2 IJmuiden HiCr iron
DSP IJmuiden HSS (R2)
DSP IJmuiden HSS (F2)
DSP IJmuiden HiCr (F1)

work roll performance in tonnes/mm

(total, including incidents)

HSS/HiCr iron finishing mill work roll performance

28000
26000
24000
22000
20000
18000
16000
14000
12000
10000
8000
6000
4000
2000
0

tonnes/mm
including incidents

FY10

FY11-Q1

FY11-Q2

FY11-Q3

FY11-Q4

FY12-Q1

FY12-Q2

FY12-Q3

FY12-Q4
8

HSM Port Talbot HSS

HSM Jamshedpur HSS
HSM Llanwern HSS
DSP IJmuiden HSS (R2)
DSP IJmuiden HiCr (F1)

HSS/HiCr iron finishing mill work rolls: trip length

6000
Av. work roll trip length (tonnes/trip)

Rolls KPI monitoring over

time (TSG HSMs) 2

tonnes/trip

5500
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
0

FY10

Av. work roll stock loss per trip

(total, including incidents)

FY11-Q1

FY11-Q2

FY11-Q3

FY11-Q4

HSM Port Talbot HSS

HSM Jamshedpur HSS
HSM Llanwern HSS
DSP IJmuiden HSS (R2)
DSP IJmuiden HiCr (F1)

HSS/HiCr iron finishing mill work rolls:

stock losses

1.6

HSM Port Talbot HiCr iron

HSM Jamshedpur HiCr iron
HSM2 IJmuiden HiCr iron
DSP IJmuiden HSS (F2)

mm/trip

FY12-Q1

FY12-Q2

FY12-Q3

FY12-Q4

HSM Port Talbot HiCr iron

HSM Jamshedpur HiCr iron
HSM2 IJmuiden HiCr iron
DSP IJmuiden HSS (F2)

1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
FY10

FY11-Q1 FY11-Q2

FY11-Q3

FY11-Q4 FY12-Q1

FY12-Q2

FY12-Q3 FY12-Q4

Roll wear scale defects

Banding scale
Roll wear scale / Banding scale
A strip that locally has a band with a damaged
surface, often with a higer roughness and
sometimes with remnants of scale particles that
have become rolled in.
When severe this defect will lead to rejection.

Strip surface
examples

Origin:
Irregular / excessive work roll surface degradation,
usually in the early finishing mill stands
Conventional HSMs: F2/F3 most sensitive; sometimes
F1 or F4 also affected
DSP IJmuiden: R2 most sensitive

Work roll surface

example

10

Surface degradation mechanisms

of hot mill work rolls

Thermal fatigue
Contact fatigue

cracking
Surface
degradation

Oxidation
Corrosion

Oxide layer
Oxidised cracks

Abrasive Wear

Wear profile

Roughness
Pitting
Comet tails
Peeling
Banding

11

Work roll surface degradation in hot mills

influence factors
Process
Strip surface
temperature
Contact time
Scale thickness on strip
Roll cooling
Rolling loads
Temperature
Atmosphere
Water coolant
(composition, T(C))
Friction coefficient
Particles or abrasive
components in scale
Slip
Rolling loads
Rolling incident impact
Strip strength

Factors affected by rolling

Advanced High Strength
Steel coils shown in purple

Thermal
fatigue
Contact
fatigue
Roll
OxidationCorrosion
Abrasive
wear
Spallings/cracks/
bruises from mill
incidents (cobbles,
tails, )

Roll properties
Fatigue strength
Thermal expansion
coefficient
Yield strength at contact
temperatures
(~500-600C)
Fatigue strength
Yield strength at
lower temperatures
Carbide distribution
Roll shell chemistry
Heat treatments
Wear resistance
Roughness
Incident resistance
12

Work roll surface deterioration

- thermal and contact fatigue
THERMAL FATIGUE
 cracks perpendicular to roll
surface
 induced by heat input from strip
influence of strip and roll cooling

most pronounced at F1, F2, F3

Influence of roll properties

CONTACT FATIGUE
 cracks parallel to roll surface
 induced by mechanical forces (rolling action)

Influence of reduction, strip hardness, temperature

Influence of roll properties

Mostly initiated in carbides

13

Thermal fatigue and contact fatigue

Thermal fatigue
& contact fatigue
Thermal fatigue
E1, HSS, Llanwern

E1, HiCr,
HSM2 IJmuiden
pitted roll

Surface of
HiCr iron work roll
with thermal pitting

0.8 mm

Corrosion in cracks aggravates roll surface degradation

Limit of 400 ppm

Cl-

14

max. introduced for HSM roll coolant

Hot strength of hot mill work roll materials

HOT HARDNESS
(Rockwell A -30kg)

Range of work roll-strip

contact temperatures
in finishing mills

80
Hardness (RCA)

75
70
ICDP
HSS7
Hi-Cr

65
60
55
50
45
0

100

200

300

400

500

600

700

Temperature (C)

Small contact temperature variations already

lead to large strength variations

15

Work roll degradation process

No defect ( + fire cracks )

Oxidation /
wear
phase

Oxidation (+ fire cracks )

Wear phase (+ fire cracks )
Pitting (+ fire cracks )

Degradation
phase

Comet tails (+fire cracks)

Peeling
Banding
Unstable oxide layer
16

Oxide layer on work roll

Oxide layer formed

by strip oxidation

upper
work
roll

Oxide layer formed

by work roll
surface oxidation

17

Importance of work roll oxide

Lengthen oxidation/wear phase in first part of rolling schedule

 Create a stable oxide film on work roll to

Delay thermal fatigue

Delay onset of degradation

Stable oxide layer

Unstable oxide layer

(2352 Tonnes rolled)

A thin oxide layer (2m) prevents
roll surface degradation

(1356 Tonnes rolled)

18

Roll oxide growth / wear balance

1 revolution
6,E-05

BITE

4,E-05

oxidation (mg/cm)

2,E-05
balance (mg/cm)

0
-2,E-05
wear (mg/cm)

-4,E-05
-6,E-05
-10

-5

10

Angle

19

Roll oxide evolution during different

campaigns

Oxide
thickness
on roll

Roll oxide too thick

(risk of peeling)

Roll oxide too thin

Coilnumber in campaign

Optimise product scheduling !!!

20

Scale defects and work roll surface deterioration

during a campaign - influence of scheduling
Scale defect occurrence (SIS data)

Finishing gauge

1.5 mm

Fmeasured/Fmodelled, stands F1,F2,F3

Coilnumber in campaign

21

HSM2 campaign with many IF steel bars

hot rolling programme with many IF steel bars

1000

10

950

900

850

800

finishing gauge (mm)

average FT (C)

heavy work roll degradation towards programe end

FT av (C)
gauge (mm)

750
0

50

100

150

200

coil number

Start of severe roll wear scale defects

22

(Micro)slivers
(micro)sliver = (Small) lamination of typically 10 to 20 m thick
sometimes with comet-shaped cooling stain which becomes visible on the runout table
origin: steel plant or hot strip mill
If HSM origin: potentially due to worn/damaged work rolls or edgers

Microscopy image
(section along rolling direction)

23

Origins of (micro-)slivers
Various root causes:
inclusions or cracks from casting plant

rolled-in primary scale; or

intercrystalline corrosion/grain boundary
weakening in reheating furnaces

rough/degraded work roll or edger roll surfaces

laps caused by other mechnical damages of

the steel surface

Extreme
degradation R2
work roll
24

Formation of internal oxidation products

around defects
O2, H2O, CO2

Iron oxides

O2, H2O, CO2

Iron oxides

Diffusion
products
(Mn,Ti,Al,..)-Ox

Wide, open crack

Narrow, closed crack

Oxidising gases have free access

to the internal defect surface.

No zone with diffusion products

Oxidising gases have no access

to the internal defect surface.

A zone with diffusion products
developes (at high T, t)
25

Internal oxidation zone indicator for defect origin

x = [(2NODO/nNZ) * t]1/2

DO = DOexp(-Ea/RT)

t =
NO =
DO =
NZ =

Ea = the activation energy

R = the gas constant
T = temperature

time
molar fraction dissolved oxygen (O) in the surface layer
diffusion coefficient of O in the steel
molar fraction of the impure alloying element Z in the steel
(Z is e.g. Mn, Ti, Si, Al)
n = ratio of oxygen atoms/Z-atoms in the diffusion product ZOn.

Indicators for time of defect origination

x: extensiveness of zone
casting/furnaces: large (~ 100 m)
RM: small (< 10 m)
FM: absent

maximum ZOn particle size

Health warnings:
no conclusions from absence of internal oxidation products

debris pick-up may cause false conclusions

26