Alloy Indefinite Chilled Cast Iron Rolls Via Advanced Technology

Product Description

Product Description

Alloy Indefinite Chilled Cast Iron is a material between chill cast iron and grey cast iron.The sizes, shapes and distributions of graphite and carbide are controlled by the chilling effect and the contents of alloy elements. The addition of alloy elements such as Manganese, Nickel, Chromium, and Molybdenum changes the matrix microstructure from pearlite, bainite to martensite. The present of small amount of fine graphite enhances the roll's resistance to spallling, thermal crack and wearability. This roll has small hardness gradient in the working layer of roll barrel and is suitable to medium and finishing stands for bar, wire and section mills.

MATERIAL	GRADE	CHEMISTRY									BARREL HARDNESS   (HSC)
		C	Si	Mn	Cr	Ni	Mo	V	W	Nb
Indefinite Chilled  (IC)	IC III	2.90-3.60	0.60-1.20	0.40-1.20	0.70-1.20	2.01-3.00	0.20-1.00				38-55
	IC IV	2.90-3.60	0.60-1.50	0.40-1.20	1.00-2.00	3.01-4.00	0.20-1.00				35-50
	IC V	2.90-3.60	0.60-1.50	0.40-1.20	1.00-2.00	3.01-4.80	0.20-2.00	0.20-2.00	0.00-2.00	0.00-2.00	40-50

  

		TYPICAL PHYSICAL PROPERTIES
Material	Tensile Strength (N/mm^2)	Bending Strength(N/mm^2)	Elongation(%)
IC	400-500	700-1000	0.2-0.5

 

Detailed Photos

 

Technology

--MELTING

TSR Rolls factory is equipped with a variety of smelting equipments, such as EBT electric arc furnace, LF double-bit refining furnace, VD-VOD vacuum furnaces and etc. Advanced smelting equipment supplemented by temperature control, component analysis and other testing equipment ensure that each furnace is in line with the requirements of molten steel.

Steel Foundry

• EBT Arc Furnace; Capacity 55T
• Ladle Furnace, Double position; Capacity 55 T Each
• Vacuum Degassing VD + VOD, 9 units; Capacity 90 T Each
• Medium Frequency Induction Furnaces, 2 sets; Capacity 20 T Each

Large Rolls Foundry

• 2 x 20 T Medium Frequency Induction Furnaces
• 2 x 10 T Medium Frequency Induction Furnaces
• 2 x 7 T Medium Frequency Induction Furnaces
• 2 x 3 T Medium Frequency Induction Furnaces

Small Rolls Foundry

• 2 x 3 T Medium Frequency Induction Furnaces
• 2 x 1.5 T Medium Frequency Induction Furnaces
• 2 x 1 T Medium Frequency Induction Furnaces

--CASTING

TSR Rolls applies advanced roll casting technology to first-class foundry equipment. Our main production processes use computers to control and select parameters automatically. So we can ensure that each batch of rolls has consistent production process control. Every step is traceable by our Electronic recording system. Whether it is static casting or centrifugal casting, our products have excellent performance.

7 Horizontal Spin Casters (Centrifugal Machines)

• 1 Unit Ø 1.600 mm x 4.500 mm B.L.
• 1 Unit Ø 1.400 mm x 3.000 mm B.L.
• 2 Units Ø 800 mm x 2.600 mm B.L.
• 1 Unit Ø 500 mm
• 2 Units Ø 300 mm

Plus a complete set of chills, chillers and moulding tackle to cast all kind of rolls including big section rolls with the barrel shaped with grooves and collars in as-cast condition.
 

--HEAT TREATMENT

During the manufacturing process of rolls, many materials need to pass one or more heat treatment to further achieve the most appropriate mechanical properties and good microstructure. The resistance furnace of TS ROLL can achieve multi-point precise temperature control to ensure uniformity of the furnace temperature. Between different furnaces, we use a unified computer control to achieve the furnace heating and cooling consistency in order to ensure the rolls from different furnaces with same microstructure and performance.

• Differential Heat Treatment Furnace Ø 1.600 mm x 2.800 mm B.L.
• Spray quenching machine, Maximum capacity: Ø1800mm rolls
• Electrical fumaces, Maximum capacity: 200T 18 sets - bogie type
• 7  sets - low-temperature
• 11 sets - high temperature

--MACHINING

TSR Roll has a machining shop of more than 15.000 square meters, including the lathe, boring machine, grinding machine and other modern processing equipment for rolls. Thanks for the first-class operator working on high-precision CNC equipment, it is easy to produce the rolls with various kinds of grooves and precise tolerances.

• CK61160 CNC Lathe, Maximum capacity: 32T
• MK84200 CNC Grinding machine, Maximum capacity: 50T
• C9125*6/63 Turing and Boring machine, Maximum capacity: 63T
• T6920D Boring machine

    
--QUALITY ASSURANCE  

The high performance requirements of today's mills require reliable rolls capable of remaining in the production cycle longer than ever while still assuring a high quality of the rolled products. TS Rolls has built a consistent quality control throughout the manufacturing process. Our aim is supplying the customer with reliable rolls capable to perform better, contributing to customer benefit, cost reduction and satisfaction.

Since the beginning TS Roll obtained the ISO 9001:2008 Quality Management System Certification. Based on our consistent adherence to the quality management, TS Roll products quality has been universally acclaimed by dozens of customers worldwide.

• Emission Spectrometer ARL - 3460; Two sets
• Carbon & Sulphur Analyzer CS-80
• Hydrogen & Oxygen Analyzers
• Thermal Analyzer
• Hardness Testers (Portable and Laboratory sets)
• Ultrasonic Testing Equipments (Several units)
• Material Testing Machine WAW-600
• Charpy Impact Test Machine JSB-300

 

Service & Support

At TSR Roll, we are focused on the roll service. Our Technical Service will help you to solve questions about roll maintenance, roll wear, roll damages, roll configuration, shape of the roll, surface hardness, roughness, temperature distribution and damage inspection among others. The aim is reducing the Total Cost of Operation for the customer by supplying reliable rolls and advanced roll service always with strict adherence to the delivery time.