Failure of Nickel Coating on a Copper Mold of a Slab Caster
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Copper molds are critical components in the continuous casting of steel. Surface condition of the mold directly affects product quality, and premature failure/low wear life affects the output of the continuous casting plant. This paper presents the failure analysis of a nickel coating on a copper plate during a plant trial using in situ ultrasonic testing for coating thickness evaluation and in situ testing to confirm the loss of coating. The failure analysis indicated maximum coating wear near the bottom corners of the mold. More wear was found on the wide end face compared with that observed on the narrow face. On top portion of the mold, wear was almost negligible. Based on the wear profile obtained during trial, it was recommended that the coating on the bottom portion of the mold have a higher hardness to improve mold life.
KeywordsFailure analysis Nickel coating on copper mold Ultrasonic testing
The authors are thankful to the management of TATA STEEL for giving permission to publish this paper. Thanks are also due to the staff of LD-2 Slab Caster for their cooperation during in situ ultrasonic and hardness measurements on the shop floor.
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