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Steel
Cost reduction program and smart maintenance & repair solutions.
Industries
Steel
Cost reduction program and smart maintenance & repair solutions.
Industries
Steel
Cost reduction program and smart maintenance & repair solutions.

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Hot rolling plants

Extreme work loads for rolls

In steel hot rolling plants, rolls are critical parts that are used for conveying and forming slabs and plates at a very high temperature. The extreme working loads as well as the high temperature wear-out the rolls surface and, as a result, parts are damaged. Maintenance managers regularly have to decide to either scrap these expensive parts or try to repair them according to OEM specifications.

Rolls protected by spray & fuse

Coated by highly skilled operators

OEMs usually provide parts that have the surface coated with high wear resistant alloys such as Eutalloy® RW 12496. This coating is applied first by spraying a powder on the roller surface and then by fusing it just above the liquidus temperature. The process allows the coating to offer its best wear resistant properties and to perfectly bound on the steel substrate. On long and heavy parts, fusion is extremely difficult to be done correctly. Just after the spraying step, the part must be pre-heated homogeneously and kept in temperature while several torches fuse the powder all along the roll. In 2m long massive rolls, fusion may require up to 7 hours and any variation in temperature may result on an irregular surface quality. Since the part is exposed to very high temperature, deformation is also critical, especially on rolls made with thin wall tubes. Finally, if cooling is not well managed, thermal stresses can be so high that cracks may appear on the overlay. Our well-equipped service workshops as well as more than 10-years experience  allow us to offer high quality overlays. Parts are coated by highly skilled operators that follow strict manufacturing methods. They regularly apply several powders according to what has been defined by OEMs.

Rolls protected by laser cladding

Reduction of grinding and machining costs

Since the installation of laser cladding technology in the Castolin Eutectic Services Centers the wear protection of key tools such as rolls and guides has been raised to a new level. The utilization of 8kW High Power Direct Diode (HPDD) with automation leads to flexible production and superior quality. In addition, the powerful laser enables high deposition rates that can reduce the cost of the cladding operation. Compared to standard welding techniques, the dissolution of the carbides and the dilution of the cladding material are the lowest that can be achieved. As a result, the wear-resistance is maximized and the service-life is longer. The unique broad beam (up to 23mm wide) produces a flat coated surface that minimizes subsequent machining or grinding. Rolls can often be used as welded without further processing. The low heat input of the laser process means the lowest distortion of large and thin wall parts that can easily be cladded.

Operating in extreme environments

Sinter crushers

In steel plants, equipment that processes sinter at very high temperature is exposed to severe wear conditions. In particular, sinter crusher that has to ensure large through-put must be wear-protected in order to avoid expensive maintenance and frequent plant shutdowns. Maintenance Managers agree that standard solutions available on the market are not sufficient for their needs. Rotors and breaker bars must regularly be replaced with new ones.
The insufficient wear resistance of the standard solutions is due to three main factors:

•    the sinter high temperature that reduces the hardfacing characteristics,
•    the sinter abrasive nature that wears-out the parts,
•    the high impacts that destroy brittle hardfacings.


Outperforms standard solutions by at least a factor 3

Unique e3 techology

e3 is a legally protected solution specifically developed for improving steel sinter crusher productivity and service life. This solution is born after 4 years of tests made in laboratory as well as on real working conditions. It is based on a unique Castolin Eutectic high temperature wear-resistant alloy that offers extreme resistance even when impact and abrasion are present. e3 is particularly suitable for protecting the critical sinter crusher parts such as the rotor discs, teeth and breaker bars. On-site tests have shown that e3 outperforms standard solutions by at least a factor 3. In addition to increasing service life, the geometrical shape of the parts is preserved, which ensures better crusher efficiency compared to standard solutions.

Our engineers can design a specific solution for your own needs

e3 benefits

In addition to boosting part service life, e3 allows you:

•    to reduce frequent sinter crusher maintenance and plant shutdowns,
•    to get higher crusher productivity by preserving teeth shape,
•    to reduce purchasing costs of new parts,
•    to avoid using complex water-cooled breaker bars.

Made by laser cladding

Sieves manufactured in our workshops

We offer a comprehensive range of wear-resistant sieves with round, square or oval apertures manufactured from 3 mm thick or higher, perforated sheets. We also manufacture tailor-made solutions according to specific customer requests. Our production technology uses a state-of-the-art, high power laser cladding installation. This system ensures highest quality wearfacing coatings of tungsten carbides dispersed in a nickel-based matrix to protect standard perforated steel sheets with variable mesh sizes.

Much better than standard steel

10 times higher service life 

The ultra hard tungsten carbide phases which are homogeneously distributed within a self-fluxing, tough nickel-based alloy matrix, provide:

  • Extreme wear resistance performance against abrasion and erosion up to 10 times higher than standard, monolithic heat-treated steel alternatives.
  • Withstands operating service temperatures up to 400°C. For even higher service temperature requirements, a diverse range of special alloy systems may be proposed to meet specific customer needs.

Modern Castolin Eutectic LaserClad technology uses a focused laser beam to ensure low heat input welding conditions, which translates into extremely effective, wear protective coatings on industrial parts.

Many advantages over traditional techniques

Tailor-made for your needs

Advantages over traditional hardfacing techniques include:

  • Very low dilution which maintains the intrinsic wear resistant properties intact.
  • Minimal dissolution of wear resistant tungsten carbide phases into the matrix to improve protective coating performance
  • Limited substrate deformation for easy installation and better service life
  • Lowest degradation of base metal properties relative to other fusion cladding processes.

Our workshops are fully equipped with laser, plasma and wearfacing welding technologies, water cutting systems, rolling-bending equipment to manufacture tailor-made sieve solutions.

Blast Furnace components

Tuyere Coolers

Extensive in-process damage to the external diameter of the Tuyere Cooler component, used in Blast Furnace operations, is a common occurrence and can lead to reduced processing capability and equipment downtime. This is especially pertinent when the substrate damage results in the Tuyere becoming lodged in the parent housing and having to be forcibly removed. Tata Steel together with Castolin Eutectic I Monitor Coatings Limited have developed a thermal spray deposition which would help negate the potential damage to the component and thus extend its useful processing life by reducing the build up and adhesion of Blast furnace by-products.

Tuyere coolers that exceed your expectations

HVOF coating

After extensive trials a composite coating structure comprising of a High Velocity Oxy Fuel (HVOF) deposited Nickel-Chromium coating together with a thermally converted slurry addition was used to protect the affected external surface. This coating produces a pore-free surface which inhibits the adhesion of the process by-products whilst protecting the substrate from extensive wear by chemical erosion.

CastCoat from Monitor Coatings

Protect the heart of your Continuous Casting Machine

The CastCoat hard composite coating was developed  by Monitor Coatings, the Castolin Eutectic subsidiary in the UK, for steel industry applications in particular for coating continuous Caster copper mould plates, for more than 20 years. Tests have shown that the coating is tougher than any other copper mould plate coating available. It has a low coefficient of friction which helps reduce sticker alarms and the coating is inert to liquid steel and casting powders. The coating system has no effect on mould level detectors or electromagnetic stirrers. It has also been proven that the coating has negligible effect on heat transfer rates.

Now a mature technology

Up to 6 times life-prolonging factor

With years of field data behind the coating, significant copper plate life improvements have been demonstrated: 3 – 4 times for thick slab casters and up to 6 times for thin slab caster narrow plates, accompanied by improved product shape. In operation, the coating has been shown to enable extended casting runs through dramatic increases in wear resistance. Eventual progressive degradation of the coating occurs due to the thermal fatigue in high stress positions. Now a mature technology with a worldwide customer base, CastCoat continues to provide users with reduced costs/tonne.

New compact HVOF device

Can also be applied to tube moulds

By coating all four faces of the mould, dimensional stability is retained throughout the campaign, leading to sustained and effective product shape and shell growth. The lack of appreciable wear means longer campaigns are possible between mould exchanges, achieving higher caster availability. In addition, the protection offered by the coating gives extended copper plate life, resulting in annual copper savings and delivering significant reductions in both on and off-line maintenance costs. With the recent development of a compact HVOF device, the CastCoat Composite Coating can now be applied to tube moulds.

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