1.

0 Introduction:
1.1 Continuous Casting Process:
In continuous casting the molten metal is transferred rapidly to the caster by a
ladle from the basic oxygen furnace or the electric furnace. The molten steel is poured
into a holding vessel known as a tundish. Tundish controls the flow and distributes the
steel into a water cooled mould. The mould gives the strand (metal) it’s desired size and
holds the molten steel long enough to form solid shell. Located at the bottom of the
mould is a dummy or starter bar that supports the initial cast and is lowered and starts the
movement of the strand. The casting process can last for hours at a time as the molten
steel can be poured continuously into the mould.

As the strand is lowered, the temperature is controlled by a system of water spray.

Many rollers guide and support the strand as it moves through the bending zone. These
are called caster rollers. The strands then enters the straightening section where there are
rolls for straightening and pinch rolls for pulling the strand through the caster . After the
strand is horizontal slabs are cut into specific lengths and are removed by a roller table.
Figure 1 reveals the continuous casting machine.

1.2 Description of Continuous Caster Rollers:

A continuous casting machine to produce iron slabs or billets has a casting arch,
in which the rolls are arranged in individual segments. These rollers may vary in length
from 18”-110” and in diameter from about 4”-23”. However many caster rolls run 50”-
72” in length and 9”-16” in diameter.
These rolls are the highest stressed components in the system. At the beginning of
the casting process the rolls are subjected to very high alternating mechanical, corrosive
and thermal stresses, which in turn results in considerable wear. The economical aspect
of a continuous casting machine is determined by the service life of these rolls. These
rolls are made from low alloyed, heat resistant CrMo(V) steels. They have low resistance
against fatigue corrosion.
Generally the hardness of the caster roller is in the range of 35 to 45 RC. Table 1
shows commonly used base materials alloys for the production of continuous casting
rolls.
 Table 1. Composition of Alloys of caster rollers

Alloy Name C Mn Si Cr Mo V
X20Cr13 0.17-.020 0.70 0.40 12-13.0 - -
16CrMo44 0.16 0.60 0.30 1.05 0.47 -
21CrMoV5,11 0.17-0.25 0.50 0.25 12-15 1-1.2 0.25-0.35
42CrMo4 0.35-0.42 0.65 0.30 1.1 0.20 -
25CrMo4 0.22-0.29 0.65 0.25 1.0 0.20 -

FIGURE 1. CONTINUOUS CASTING MACHINE

1.3 Various Deterioration of Caster Rollers:

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 These caster rolls are subjected to various types of roll surface deterioration
which reduces their sizes below the minimum usable diameter. They are subjected to
three main types of roll surface deterioration.

a. Abrasion:
Mill scale is present on the strand which causes abrasive wear on the roll surface.
Further adhesive wear is caused by the constant rolling of the strand over the rolls.(Metal
to metal wear ).

b. Thermal Fatigue:
Commonly known as ‘fire cracking’. This is a result of the roll surface being
subjected to heat the strand and the cooling of the water pray.

FIGURE 2. THERMAL FATIGUE

The constant expansion and contraction of the roll surface causes a great deal of
strain and eventually causes the surface to crack at high temperatures.

c. Corrosion:

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 The air mist water spray that controls the strand temperature can create an acidic
condition from the mould powders used in the casting process. This high temperature
oxygen rich corrosive medium can reduce or eliminate the passivated oxide on the
stainless steel overlay. The cyclical process leads to corrosive attack and depletion of the
roll surface.
This extent of the roll surface deterioration of caster rolls is dependent on the
placement in the caster, roll overlay chemistry, roll function, roll size and type of alloy
being cast. Due to this deterioration of the roll surfaces it becomes necessary to rebuild
the rolls every 9-15 months, as it is not economical to purchase new rolls every time.
Rebuilding of the rolls is done by welding process called submerged arc
welding.

1.4 Submerged Arc Welding Process :-

Submerged Arc Welding (SAW) is an arc welding process that fuses together the
parts to be welded by heating them with one or more electric arcs between one or more
bare electrodes and the work piece.
The submerged arc welding process utilizes the heat of an arc between a
continuously fed electrode and the work. The heat of the arc melts the surface of the base
metal and the end of the electrode. The melted metal of the electrode is transferred
through the arc to the work piece where it becomes the deposited weld metal

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 FIGURE 3.SUBMERGED ARC WELDING

Submerged Arc is obtained from the blanket of the granular flux, which is laid
directly over weld area. The flux close to the arc melts and intermixes with the molten
weld metal and helps purify and fortify it. The flux forms a glasslike slag that is lighter in
weight than the deposited weld metal and floats on the surface as a protective cover.
The weld is submerged under this layer of flux and slag , hence the name submerged arc
welding.

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2.0 Background :
Before 1940’s, after the wear of the rollers, they were replaced by new ones every
9 to 15 months. In mid 1940’s, reconditioning of these continuous caster rollers by
welding was pioneered in Europe. These were with varying degree of success
In 1946, Republic steel prepared an article on Weld Surfacing Work Rolls which
was the first article on surfacing steel mill rolls published in USA. Since that time it has
been well documented by a number of qualified U.S rebuilding shops that with the
submerged arc welding process and controlled procedure most worn steel mill rolls can
be rebuilt and machined to original dimensions at a cost substantially lower than the cost
of new rolls. In most of the cases when rebuilt rolls have worn beyond specified limits
and indeed the wear of life of property rebuilt rolls well exceeds that of a new roll they
can usually be rebuilt again and again.

3.0 Methodology:
The extent of the roll surface deterioration of the rolls is dependent on the roll
placement in the caster, roll overlay chemistry, roll function, roll size and the type of
alloy being cast. Rolls will wear differently from machine to machine and within
machine.

3.1 Preparation And inspection of Rolls Prior Welding:

3.1.1 Preliminary Visual Inspection:

A preliminary visual evaluation should be completed by appropriate
personnel to determine which rolls will be reconditioned and which may require further
evaluation before being scraped.

3.1.2 Cleaning And Protection:

Dirty rolls are sometimes cleaned by sand blasting, use of solvent or cleaning
with steam. Portions of the roll not to be rebuilt (journal, bearing areas, keyways, thrust

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surfaces) many have to be protected from oxidation by application of a suitable coating
material. Protection from damage to rolls in area where the lifting and handling device
are used should be considered.

3.1.3 Stress Relieving Prior To Preweld Machining:

It is the most recommended step to perform a stress relief/tempering heat
treatment prior to undercutting the surface to rebuild. The stress relief temperature should
be kept at about 38°C below the original tempering temperature of the roll base metal.
This heat treatment not only relieves the complex stresses within the roll but
also reduces the surface hardness to a level that does not require expensive cutters or time
consuming special machining practices. The stress relief temperature is based on the roll
material chemistry and is usually between 480°C and 565°C. The soaking time should be
approximately ½ hour per inch of roll thickness.
Heating rates of 66-93°C per hour are recommended up to a temperature of
about 260°C. When heating above 260°C a heating rate of about 38-66°C per hour is
suitable. On cooling reverse the process. Cooling to at least 205°C (preferably 148°C)
should be done in furnace.
Most lubricants, coatings and other contaminants are conveniently burned
off during the heat treatment cycle. This operation is particularly necessary where all of
the old roll mill overlay weld metal has not been worn off.

3.1.4 Undercutting:
Undercut the surface to rebuilt by machining to remove scale, rust, carburized
material, flaws and mechanically or thermally fatigued metal. Depth of undercut may
vary from 1/8“to 1/4“and in the case of scaling or deep cracks, up to about 2”.

3.1.5 Inspection:
Check for defects using magnetic particle, dye check or ultrasonic inspection.
Cracks should be removed and inspection repeated to ensure soundness.

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3.2 Preheating And Interpass Temperature Control:
3.2.1 Preheating:
Control of preheat and the interpass temperature before and during welding is
necessary to obtain uniform overlay harness and prevent heat affected zone under bead
cracking and delayed hydrogen cracking. Ideally preheating should be accomplished
gradually in a temperature controlled furnace to a temperature and soak time approximate
for the roll alloy and mass. Below the temperature of 260°C a heating rate of 66°-93°C
per hour is acceptable, while above 260°C a heating rate of 38°-66°C per hour is
common.
The temperature should be adequate to allow for cool-down in the time elapsed in
moving the roll from the furnace to the welding station. One rule of thumb calls for a
soak time of ¼ hour to ½ hour per inch of the roll diameter. Generally, heating to about
425°C and soaking for about 6-8 hours is common
.

FIGURE 4. PREHEATING

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 3.2.2 INTERPASS TEMPERATURE CONTROL :-

The interpass temperature should not deviate more than about 50°C to 38°C
below the preheat temperature. If the roll is allowed to cool significantly below the
preheat temperature during welding, transformation to martensite could occur; if this
happens, subsequent layers of the weld metal will then temper the martensite to varying
degree of hardness resulting in hard spots during machining and very soft spots
underneath the final layer. Insufficient roll body temperature during welding may thus
cause uneven roll wear to develop. Therefore, it is imperative to preheat and maintain the
roll temperature above the start of martensite transformation temperature of the overlay
throughout the welding process. The martensite transformation temperature for many
12% Cr steel overlay is 232°C-288°C.
No preheating is required for all base materials with carbon content less than
0.2%. For all base materials with carbon content more than 0.2% preheating to 148°C at
rate of 120°C per hour.

3.3 WELDING PROCEDURE ( SUBMERGED ARC

WELDING):-

3.3.1 WELDING PARAMETERS AND DEPOSITION

RATES:-

Generally, welding wires of size 3/32”,1/8”and 5/32” are used for the welding
process. The typical welding parameters and deposition rates of these wires are:

Diameter 3/32” 1/8” 5/32”

Current-Amps. 350-500 400-500 450-600
Voltage –volts 25-29 26-31 27-32
Wire extension – 1”-1 ¼” 1 ¼ “-1 ½ “ 1 ¼”- 1 ½ “
inches
Deposition Rate- 14-22 16-24 17-25
lbs/hr

If lower end of the current range is used, the lower end of the voltage applies.
Same way for high end of the current range and high end of voltage range.
The welding current is the main parameter that influences the weld deposition
rate. The electrode melt off rate increases with increased deposition rates. A constant
current a smaller diameter wire will have a higher deposition rate than a larger diameter
wire due to higher current density applied across the smaller cross-section of the small
diameter wire.

3.3.2 EFFECT OF WELDING PARAMETERS:-

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 3.3.2.1 CURRENT :- FIGURE 5. EFFECT OF CURRENT
The penetration of the weld
bead into the roll material increases
due to increased input of heat energy
directly dependent on the current level.
Increased penetration leads to
increased weld metal dilution with the
roll material and may results in
solidification cracking.

3.3.2.2 VOLTAGE:
-
The main effect of the voltage
is on the weld bead width. Generally,
FIGURE 6. EFFECT OF VOLTAGE
as the voltage is increased the weld
bead width increases and the weld
bead reinforcement decreases. Too low
voltage may cause weld bead undercut
which can lead to poor slag
detachability and slag entrapment.
Voltage has very slight influence on
the deposition rate.

3.3.2.3 ROTATING
SPEED:- FIGURE 7. EFFECT OF
Increasing the rotating surface SPEED
speed will decrease the width and
decreasing the speed will increase the
width. The speed must be adjusted
with the current and voltage to produce
the ideal weld bead.

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3.4 RECOMMENDED LEADS AND ROTATING SURFACE
SPEED:-

The position of the wire with respect to the top centre – eccentric distance and
eccentric angle – is very important to achieve good bead shape and good slag removal.
The eccentric distance is known as lead or offset. The position of wire must be such that
the molten weld pool solidifies as it passes top centre.
Leads of ¾ “to 1 ¾ “ (approximately 5% of the roll diameter) up to about 42” are
used, depending on diameter of roll.

ROLL DIAMETER LEADS

3”-18” ¾”-1 ¼”
18”-36” 1 ¼”-1 ½”
36”-42” 1 ½”-1 ¾”
42”-48” 1 ¾”-2”
48”-60” 2”-2 ½”

The rotating surface speed is the number of inches passing a given point in one
minute.
Linear surface speed = πDN
Where π=3.14, D= diameter and N= rpm
If the surface speed is increased a narrower bead is obtained, while if speed is
decreased wider bead is obtained.

3.5 WELD BEAD DILUTION AND OVERLAP :-

When filler metal/electrode of different composition from that of base metal, the
weld bead may be expected to exhibit a composition lying somewhere between that of
the filler metal and that of the base metal. This effect is called dilution. To overcome the
effect of dilution multiple layers of overlay.
Welding bead overlaps of 30%-50% are commonly used. An overlap closer to
50% on initial layers would reduce dilution. Excessive overlap 70% or above may cause
bead roll-over and slag entrapment.

3.6TEMPERATURE CONTROL DURING THE WELDING

PROCESS:-

During the welding process, if the slag becomes difficult to remove for the grade
of flux used, this is an indication that the roll has become too hot in the welding area. If

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this happens delay welding for a few minutes or move the welding arc or arcs about 12”
away from their present location. Temperatures are checked as possible at all times.

3.7 DIMENSIONAL ACCURACY:-

Dimensional accuracy is important; allowance must be made for the expansion of

the roll diameter due to preheating, welding and stress relieving. Over welding about 1/8”
on the diameter is common practice to allow contraction.

3.8 PROCEDURE FOR MORE THAN 1” TOTAL DEPOSIT

PER SIDE OF ROLL:-

Where more than about 1” of total deposit on the roll radius is required an
intermediate stress relief heat treatment should be considered to relax hoop stresses
which increase as the roll diameter increases and to minimize the danger of hydrogen
assisted cracking. Each layer is usually about 1/8 “deep so that normally 8 layers of 1/8”
would be required for a total deposit of about 1” per side of roll.

FIGURE 8. WELDING OF ROLL WITH FOUR TORCHES

A. Firstly ½” per side a built up layer is applied with a low alloy steel.
B. The roll is cooled gradually to about 148°C. To avoid hydrogen cracking it is
necessary to allow the hydrogen which can come from moisture in the flux, wire
and atmosphere to diffuse out of the weld. Since hydrogen cannot diffuse out of
austenite, it is necessary to allow the weld deposit to cool to about 148°C which
allows for martensite transformation and hydrogen diffusion.
C. Once the roll reaches 148°C it can be stress relieved at 480°C-540°C for 2-4
hours.
D. Then apply hard surfacing overlay deposit using appropriate preheat and interpass
temperature and welding parameters.

3.9 SUGGESTED GRADUAL COOLING PROCEDURE:-

Gradual cooling can be facilitated by covering with an insulated
material or using an insulated enclosure such as a steel box containing sand or a pit
where some heat is provided by infrared heaters.
Typical insulating products include perlite, vermiculite, kaowool and
cerachem.

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 I. Perlite is a glossy volcanic rock chemically composed primarily of aluminium
silicates.
II. Vermiculite is the geological name given to a group of hydrated laminar minerals
which are aluminium-iron-magnesium silicates.
III. Kaowool amd cerachem are alumina silica ceramic fiber products.

3.10 FLUX CONTROL FOR CYLINDRICAL WORK:-

During the rebuilding of cylindrical parts, the granular flux must be prevented
from prematurely falling away from the welding zone. A support can be made using a
non combustible material attached to the contact nozzle or some part of the fixture
allowed to ride on the work. The flux must also be supported when welding an edge.
The flux must be fed onto the surface to be welded just ahead of the arc and
carried into the arc zone by the rotating part. When small diameter parts are surfaced, the
flux must be fed closer to the arc. Submerged arc fluxes can vary in manufacturing
method and degree of neutrality. They can also add alloying elements or be alloy
compensating. The height of the flux bed should be about 1”. Loss of the flux bed can
result in pick-up nitrogen from the air causing porosity or variation in deposit chemistry.

3.11 POST WELD HEAT TREATMENT:-

3.11.1 SLOW COOL:-

After welding is completed the surfaced roll should be placed in at furnace or

insulated enclosure and allowed to cool at a rate of less than 38°C per hour to a
temperature below martensite transformation temperature of the overlay alloy and held at
the temperature about 93°C. For several hours to minimize the temperature differential
from outside to the inside of the mill.

3.11.2 STRESS RELIEVE (TEMPER):-

Cooling from the temperature developed in welding will produce tension stresses
in the overlay. Stress relief and tempering (softening to a lower hardness and increased
ductility ) can be obtained by gradual heating to 480°C or higher (usually 540°C-620°C).
The actual temperature and time (usually ½ hour to 1 hour per inch of roll diameter) will
be determined by the roll alloy, diameter and required hardness. Cooling from the stress
relief temperature should not exceed 120°C per hour above 260°C.
When overlay is to be applied more than about 1” on the side it is advisable to
stop welding after first ½”, then cool to about 93°C-148°C and stress relieve at about
480°C-540°C for 2-4 hours before applying additional weld metal.

3.12 MACHINING:-

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 Carbide cutting tools are necessary for rough machining while ceramic cutting
tools may be required for finishing. A surface finish of less than 63 microns is
recommended to minimize the possibility of the machine tracks to act as fatigue crack
initiation.

FIGURE 9. MACHINING PROCESS

3.13 FINAL INSPECTION:-

After stress relieving and final machining hardness is checked by use of a

portable hardness tester such as Equotip hardness Tester (Wayne Tool and Supply Co.),
Penetrascope (Vickers), etc.
Roll surface must be free of any defects that could nucleate thermal fatigue
cracks. A final inspection is necessary to detect such as slag inclusion or cracks.
Inspection may be done by magnetic particle, ultrasonic or liquid penetrant (dye check)
process. Minor defects may be ground out and welded by suitable means. Major defects
are removed by circumferentially to avoid the undesirable effect of a plug weld. Local
preheat is required before welding major defects

4.0 RESULTS:-
4.1 SERVICE RECORD FROM SIDMAR STEEL
INDUSTRY:-

A 240mm diameter roller regenerated using submerged arc welding processed

23, 95,692 tonnes of steel before wearing out.

4.2 COST SAVINGS:-

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 Roll Dia. (mm) 360 460 500
New Roll £2900 $ 4900 $ 5900
Reclamation $ 1900 £ 2500 $ 2700
Saving 34% 49% 54%

The above table gives the cost differences between new rolls and the regenerated rolls.

5.0 CONCLUSION:-

The concepts and practices developed for caster roll welding can be exploited
successfully to reclaim process rolls used throughout the steel mill. The regenerating of
the rolls extends their service life 3 to 5 times the normal life.
A considerable amount of the cost saving is achieved by reclamation of steel mill
rolls.

6.0 REFERENCES:-

1) McKay Welding Products,Hobart Brothers, U.S.A , “A Guide For Submerged Arc

Welding Of Steel Mill Rolls”

2) Frederick George Payne, Dundas,Canada ,U.S Patent 4040158, “STEEL MILL

ROLL”

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3) Kolbeck, Dietmar (Steinfeld, DE) , Wobker, Hans-günter (Bramsche, DE) ,
Hugenschütt, Gerhard (Belm, DE) , U.S Patent 7178578, “CONTINUOUS
CASTING ROLL”

4) David Le Jeune (Hampshire, UK), John Morris (Hampshire, UK), Pat Collins
(Hampshire, UK), “Roll Performance in the Hot Strip Mill using Proven Welding
Technology and Specially Developed Welding Materials to Reduce Operational
Costs and Maximise Productivity”

5) Durum Verschleiss-Schutz GmbH, Germany, “REGENERATING CONTINUOUS

CASTING ROLLS”

6) Richard L Little, Tata McGraw-Hill Edition, “WELDING AND WELDING

TECHNOLOGY”

7) John Lancaster, Abington Publishing, England, “HANDBOOK OF STRUCTURAL

WELDING”

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