Skip to main content
SpringerLink
Log in

Refurbishment of Continuous Caster Rolls by Laser Cladded Fe-Cr-Ni-Mo-Co Alloy

  • Technical Article
  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

Laser cladded low carbon 12Cr-5Ni-3Mo-5Co-based Fe powder system has been implemented to improve the performance of the vertical section rolls. Compositional, microstructural, and mechanical characterizations of the cladding and substrate materials were carried out as part of the development work. The electron probe microanalyzer was used to observe the distribution of important chemical elements in the clad region. The hardness value of clad region containing almost 100% martensitic structure was found ~ 1.5 times more than the substrate value. The dilatometry test conducted within the temperature range from 100 to 700 °C shows that the coefficient of linear thermal expansion was lower for clad part than the substrate. Oxidation test was carried out at three different temperatures (200, 400, and 600 °C), where results showed that clad part possesses much better oxidation resistance than the substrate. Wear test carried out at 400 °C showed that wear loss for clad material is comparatively smaller than that of the roll material. It was found that the applied laser cladded system offers a good combination of hardness, oxidation resistance, and wear resistance compared to the conventional martensitic stainless steels (X20Cr13 grade).

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig 1
Fig 2
Fig 3
Fig 4
Fig 5
Fig 6
Fig 7
Fig 8
Fig 9
Fig 10
Fig 11
Fig 12
Fig 13
Fig 14
Fig 15
Fig 16
Fig 17

Similar content being viewed by others

References

  1. J. Viňáš, J. Brezinová, and A. Guzanová, Analysis of the Quality Renovated Continuous Steel Casting Roller, Sadhana Acad. Proc. Eng. Sci., 2013, 38(3), p 477–490. https://doi.org/10.1007/s12046-013-0119-3

    Article  Google Scholar 

  2. S. Louhenkilpi, Continuous casting of steel, Treatise on process metallurgy. Elsevier, 2014, p 373–434

    Chapter  Google Scholar 

  3. Y. Satoh, T. Yamamura, and T. Takimoto, Techniques for Long Life Materials Applied to Continuous Caster Roll, Kawasaki Steel Tech. Rep., 2001, 45, p 42–49.

    Google Scholar 

  4. B.G. Thomas, Continuous casting (metallurgy), Yearbook of science and technology. McGraw-Hill, 2004, p 1–6

    Google Scholar 

  5. M. Du Toit, and J. Van Niekerk, Improving the Life of Continuous Casting Rolls Through Submerged Arc Cladding with Nitrogen-Alloyed Martensitic Stainless Steel, Weld. World, 2010, 54, p R342–R349. https://doi.org/10.1007/BF03266748

    Article  Google Scholar 

  6. B.G. Thomas, M.A. Wells, and J. Sengupta, The Use of Water Cooling During the Continuous Casting of Steel and Aluminum Alloys, Metall. Mater. Trans. A, 2005, 36A, p 187–204.

    Google Scholar 

  7. A. Sanz, New Coatings for Continuous Casting Rolls, Surf. Coat. Technol., 2004, 177–178, p 1–11. https://doi.org/10.1016/j.surfcoat.2003.06.024

    Article  CAS  Google Scholar 

  8. G.F. Da Silva, S.S.M. Tavares, J.M. Pardal, M.R. Silva, and H.F.G. De Abreu, Influence of Heat Treatments on Toughness and Sensitization of a Ti-alloyed Supermartensitic Stainless Steel, J. Mater. Sci., 2011, 46, p 7737–7744. https://doi.org/10.1007/s10853-011-5753-8

    Article  CAS  Google Scholar 

  9. K. Kishore, M. Adhikary, G. Mukhopadhyay, and S. Bhattacharyya, Development of Wear Resistant Hammer Heads for Coal Crushing Application Through Experimental Studies and Field Trials, Int. J. Refract. Hard Met., 2019, 79, p 185–196. https://doi.org/10.1016/j.ijrmhm.2018.12.009

    Article  CAS  Google Scholar 

  10. L. Zhu, P. Xue, Q. Lan, G. Meng, Y. Ren, Z. Yang, P. Xu, and Z. Liu, Recent Research and Development Status of Laser Cladding: A Review, Opt. Laser Technol., 2021, 138, p 1–26. https://doi.org/10.1016/j.optlastec.2021.106915

    Article  CAS  Google Scholar 

  11. W. Steen and K. Watkins, Coating by Laser Surface Treatment, J. Phys. IV Proc. EDP Sci., 1993, 03, p 581–590. https://doi.org/10.1051/jp4:1993961

    Article  CAS  Google Scholar 

  12. K. Kishore, N. Jaiswal, A. Prabhakaran, and K.S. Arora, Through-Thickness Microstructure and Wear Resistance of Plasma Transferred Arc Stellite 6 Cladding: Effect of Substrate, CIRP J. Manuf. Sci. Technol., 2023, 42, p 24–35. https://doi.org/10.1016/j.cirpj.2023.01.014

    Article  Google Scholar 

  13. Z. Liu, G. Lian, C. Zhao, J. Peng, and Y. Zhang, The Forming Control Method of Ni35A+ TiC Composite Coatings on Cylindrical Substrate Deposited by Laser Cladding, J. Mater. Eng. Perform., 2023, 32, p 1333–1346. https://doi.org/10.1007/s11665-022-07160-1

    Article  CAS  Google Scholar 

  14. C. Navas, A. Conde, B.J. Fernández, F. Zubiri, and J. de Damborenea, Laser Coatings to Improve Wear Resistance of Mould Steel, Surf. Coat. Technol., 2005, 194(1), p 136–142. https://doi.org/10.1016/j.surfcoat.2004.05.002

    Article  CAS  Google Scholar 

  15. C.T. Kwok, K.H. Lo, F.T. Cheng, and H.C. Man, Effect of Processing Conditions on the Corrosion Performance of Laser Surface-Melted AISI 440C Martensic Stainless Steel, Surf. Coat. Technol., 2003, 166(2–3), p 221–230. https://doi.org/10.1016/S0257-8972(02)00782-X

    Article  CAS  Google Scholar 

  16. K. Feng, Y. Chen, P. Deng, Y. Li, H. Zhao, F. Lu, R. Li, J. Huang, and Z. Li, Improved High-Temperature Hardness and Wear Resistance of Inconel 625 Coatings Fabricated by Laser Cladding, J. Mater. Process. Technol., 2017, 243, p 82–91. https://doi.org/10.1016/j.jmatprotec.2016.12.001

    Article  CAS  Google Scholar 

  17. A. Ray, K.S. Arora, S. Lester, and M. Shome, Laser Cladding of Continuous Caster Lateral Rolls: Microstructure, Wear and Corrosion Characterisation and On-Field Performance Evaluation, J. Mater. Process. Technol., 2014, 214(8), p 1566–1575. https://doi.org/10.1016/j.jmatprotec.2014.02.027

    Article  CAS  Google Scholar 

  18. P. Maruschak, R. Bishchak, D. Baran, and L. Poberezhny, Failure Analysis of Continuous Casting Rolls Material and Physical Simulation of Thermal Fatigue Loading, Mechanika, 2013, 19(4), p 398–402. https://doi.org/10.5755/j01.mech.19.4.5046

    Article  Google Scholar 

  19. S. Lee, D.H. Kim, J.H. Ryu, and K. Shin, Correlation of Microstructure and Thermal Fatigue Property of Three Work Rolls, Metall. Mater. Trans. A, 1997, 28(12), p 2595–2608. https://doi.org/10.1007/s11661-997-0017-6

    Article  Google Scholar 

  20. Y. Lee, M. Nordin, S.S. Babu, and D.F. Farson, Effect of Fluid Convection on Dendrite Arm Spacing in Laser Deposition, Metall. Mater. Trans. B, 2014, 45(4), p 1520–1529. https://doi.org/10.1007/s11663-014-0054-7

    Article  CAS  Google Scholar 

  21. W. Chen, B. Xiao, L. Xu, Y. Han, L. Zhao, and H. Jing, Additive Manufacturing of Martensitic Stainless Steel Matrix Composites with Simultaneously Enhanced Strength-Ductility and Corrosion Resistance, Compos. B. Eng., 2022, 234, p 1–13. https://doi.org/10.1016/j.compositesb.2022.109745

    Article  CAS  Google Scholar 

  22. E. Altuncu and M. Tarım, Laser Cladding of Martensitic Stainless Steels on Armor Steels, Emerg. Mater. Res., 2019, 9(1), p 55–58. https://doi.org/10.1680/jemmr.18.00120

    Article  Google Scholar 

  23. P. Fasihi, O. Kendall, R. Abrahams, P. Mutton, C. Qiu, T. Schläfer, and W. Yan, Tribological Properties of Laser Cladded Alloys for Repair of Rail Components, Materials, 2022, 15(21), p 1–14. https://doi.org/10.3390/ma15217466

    Article  CAS  Google Scholar 

  24. Y.F. Yin and R.G. Faulkner, Physical and elastic behavior of creep-resistant steel, Creep-resistant steels. Woodhead Publishing in Materials, 2008, p 217–240

    Chapter  Google Scholar 

  25. F.C. Hull, S.K. Hwang, J.M. Wells, and R.I. Jaffee, Effect of Composition on Thermal Expansion of Alloys Used in Power Generation, J. Mater. Eng., 1987, 9(1), p 81–92.

    Article  CAS  Google Scholar 

  26. K. Chandra and A. Kranzmann, High Temperature Oxidation of 9–12% Cr Ferritic/Martensitic Steels Under Dual-Environment Conditions, Corros. Eng. Sci. Technol., 2018, 53, p 27–33. https://doi.org/10.1080/1478422X.2017.1374049

    Article  CAS  Google Scholar 

  27. V.F. De Souza, A.J. Araújo, J.L.N. Do Santos, C.A.D. Rovere, and A.M.S. De Malafaia, Kinetics Oxidation and Characterization of Cyclically Oxidized Layers at High Temperatures for FeMnSiCrNiCe and FeSiCrNi Alloys, Mater. Res., 2017, 20, p 365–373. https://doi.org/10.1590/1980-5373-mr-2017-0098

    Article  Google Scholar 

  28. A.V. Makarov, A.E. Kudryashov, S.V. Nevezhin, A.S. Gerasimov, and A.A. Vladimirov, Reconditioning of Continuous Casting Machine Rollers by Laser Cladding, J. Phys. Conf. Ser., 2020, 1679, p 42–47. https://doi.org/10.1088/1742-6596/1679/4/042047

    Article  CAS  Google Scholar 

  29. L.D. Conceição and A.S.C.M. D’Oliveira, The Effect of Oxidation on the Tribolayer and Sliding Wear of a Co-Based Coating, Surf. Coat. Technol., 2016, 288, p 69–78. https://doi.org/10.1016/j.surfcoat.2016.01.013

    Article  CAS  Google Scholar 

  30. F. Shu, B. Wang, S. Zhang, S. Sui, X. Zhang, and J. Zhao, Microstructure, High-Temperature Wear Resistance, and Corrosion Resistance of Laser Cladded Co-Based Coating, J. Mater. Eng. Perform., 2021, 30, p 3370–3380. https://doi.org/10.1007/s11665-021-05704-5

    Article  CAS  Google Scholar 

Download references

Acknowledgments

The authors would like to thank Tata Steel India for providing the essential research facilities and permitting to publish this paper. The support from the laboratory staff is highly appreciated. This research did not receive any specific grant from funding agencies in the public, commercial, or not-for-profit sectors.

Author information

Authors and Affiliations

  1. Department of Metallurgical and Materials Engineering, Indian Institute of Technology, Kharagpur, 721302, India

    Nachiketa Yadav & Debalay Chakrabarti

  2. Department of Metallurgical and Materials Engineering, National Institute of Technology, Karnataka, 575025, India

    Kumar Harsh

  3. Magod Fusion Technologies Pvt. Ltd., Maharashtra, 411026, India

    Harshad Natu

  4. Research and Development, Tata Steel Limited, Jamshedpur, 831001, India

    Kaushal Kishore & Arnab Karani

Authors
  1. Nachiketa Yadav
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Kumar Harsh
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Harshad Natu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Kaushal Kishore
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Arnab Karani
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Debalay Chakrabarti
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

NY: Conceptualization, Data curation, Investigation, Methodology, Writing–original draft. KH: Data curation, Investigation, Methodology. HN: Investigation, Methodology. KK: Data curation, Writing–review & editing. AK: Supervision, Writing–review & editing. DC: Supervision, Writing–review & editing.

Corresponding author

Correspondence to Nachiketa Yadav.

Ethics declarations

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yadav, N., Harsh, K., Natu, H. et al. Refurbishment of Continuous Caster Rolls by Laser Cladded Fe-Cr-Ni-Mo-Co Alloy. J. of Materi Eng and Perform (2023). https://doi.org/10.1007/s11665-023-08369-4

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s11665-023-08369-4

Keywords

Search

Navigation