Journal of Failure Analysis and Prevention

, Volume 14, Issue 6, pp 707–714 | Cite as

Ribbon Fatigue Spalling of a Forged Work Roll Used at a Cold Rolling Mill

  • Soma Ghosh
  • Pankhuri Sinha
  • Shivanandan Indimath
  • Goutam Mukhopadhyay
  • Sandip Bhattacharya
Case History---Peer-Reviewed

Abstract

Catastrophic failure of a forged work roll used in a cold rolling mill was investigated. The spalled roll showed fatigue arrest marks in a smooth continuous path along the circumferential direction. Characteristic features of the fracture surface were similar to that of surface initiated spalling which is known as ribbon fatigue spalling. The investigation consisted of visual observation, profiling of crack using ultrasonic testing, microstructural characterization by optical and scanning electron microscopy, XRD analysis, and hardness measurements. Ultrasonic evaluation confirmed the initiation of root crack on the roll surface followed by an extensive sub-surface propagation (~815 mm length) of fatigue crack. Microstructural analysis revealed the presence of dendritic columnar structure and coarse irregular carbides indicating improper manufacturing process. Retained austenite content (~12%) as measured using XRD was higher than the usual desirable limit for such application. These microstructural abnormalities deteriorated the fatigue resistance of the roll. Since the roll failed within few hours of the running campaign and there was no operational abnormality reported in the campaign, it can be inferred that the initiation of the fatigue crack was conceived prior to the running campaign. It was an inspection deficiency that the crack was not detected prior to the start of the campaign. Initiation of fatigue crack which could not be detected during inspection led to the premature failure of roll in the early stage of campaign.

Keywords

Fatigue Ultrasonic Metallography 

References

  1. 1.
    A.K. Roy, K.K. Mishra, G. Das, P.N. Chaudhary, Life of rolls in a cold rolling mill in a steel plant-operation versus manufacture. Eng. Fail. Anal. 7, 55–67 (2000)CrossRefGoogle Scholar
  2. 2.
    M.S. Prasad, A. Ray, S.K. Dhua, R. Avtar, S. Jha, Premature failure of work-rolls in tandem mill: some microstructural revelations. J. Fail. Anal. Prev. 4(3), 67–72 (2004)CrossRefGoogle Scholar
  3. 3.
    C.R.F. Azevedo, J.B. Neto, Failure analysis of forged and induction hardened steel cold work rolls. Eng. Fail. Anal. 11, 951–966 (2004)CrossRefGoogle Scholar
  4. 4.
    Q. Wu, D. Sun, C. Liu, C. Li, Analysis of surface and sub-surface initiated spalling of forged cold work rolls. Eng. Fail. Anal. 15, 401–410 (2008)CrossRefGoogle Scholar
  5. 5.
    K.H. Schroder, A Basic Understanding of the Mechanics of Rolling Mill Rolls, ESW Handbook (Eisenwerk Sulzau-Werfen, Werfen, 2003)Google Scholar
  6. 6.
    The European Foundry Association, Roll Failures Manual-Hot Mill Cast Work Rolls, 1st edn. A Publication of CAEF, The European Foundry Association (Roll Section), Dusseldorf, 2002Google Scholar
  7. 7.
    M. Renáta, The differences in quality of 18CrNiMo7-6 steel and its influences at deformation after carburizing, in Proceedings of 1st International Conference on Metallurgy and Materials, Brno, 23–25 May 2012Google Scholar
  8. 8.
    F. Peng, Adverse impact and countermeasures of macro segregation for ring forging product. J. Mater. Appl. 1(1), 17–20 (2012)Google Scholar
  9. 9.
    A.K. Roy, K.K. Mishra, G. Das, P.N. Chaudhary, Failure analysis of rolls of cold rolling mill in steel plant, in Failure Analysis: Proceedings of the Clinic on Failure Analysis, 18–19 February 1997, NML, Jamshedpur, pp. 37–46Google Scholar
  10. 10.
    A. Ray, D. Mukherjee, B. Sarkar, S. Mishra, Influence of microstructure on the premature failure of a second-intermediate Sendzimir mill drive roll. J. Mater. Eng. Perform. 3(5), 649–656 (1994)CrossRefGoogle Scholar
  11. 11.
    W. Patt, in Production and Properties of High-Cr-Rolls and Their Behaviour in Cold Strip Mills, Conference Proceedings on Mechanical Working and Steel Processing, vol. XXII, The Iron and Steel Society, 1985, pp. 101–107Google Scholar
  12. 12.
    H.A. Ferguson, ASM Handbook, Heat Treating, vol. 4 (ASM International, Metals Park, OH, 1991), p. 199Google Scholar
  13. 13.
    G. Pantazopoulos, A. Vazdirvanidis, Fractographic and metallographic study of spalling failure of steel straightener rolls. J. Fail. Anal. Prev. 8, 509–514 (2008)CrossRefGoogle Scholar

Copyright information

© ASM International 2014

Authors and Affiliations

  • Soma Ghosh
    • 1
  • Pankhuri Sinha
    • 1
  • Shivanandan Indimath
    • 1
  • Goutam Mukhopadhyay
    • 1
  • Sandip Bhattacharya
    • 1
  1. 1.R&D and Scientific ServicesTata Steel Ltd.JamshedpurIndia

Personalised recommendations