Analysis of Surface Spalling on a First Intermediate Roll in Sendzirmir Mills

A first intermediate roll of Sendzirmir mills was failure by surface spalling during operation. After analyzing by visual, stereo microscope, optical microscope, scanning electron microscope, glow-discharged spectrometer and hardness test, respectively, the results show that some voids and cracks existed on the contact surface as well as subsurface. Further examination verified inadequate hardness and inclusions were responsible for the failure of surface spalling.

Authors:

• Shiang-Cheng Jeng
• Horng-Shing Chiou

Keywords:

• Sendzirmir mills; surface spalling; fatigue failure;inclusion; contact stress

References:

[1] ASM 9th Edition , Forming and Forging , Metal Handbook , Vol.
14 , 1988, p352~354.
[2] ASM 9th Edition , Failure Analysis and Prevention, Metal
Handbook ,Vol. 11 , 1986, p133~134 , p340~345 , p500~505.
[3] Qiong Wu, Da-le Sun, Chang-sheng Liu and Chun-quang Li ,
Analysis of surface and sub-surface initiated spalling of forged
cold work rolls. Eng Fail Anal , 2008, 15, p401~410.
[4] Azevedo CRF, Belotti Neto J , Failure analysis forged and
induction hardened steel cold work rolls. Eng Fail Anal , 2004,
11(6), p951~966.
[5] Ray AK, Mishra KK, Das G, ea al. , Life of rolls in a cold rolling
mill in a steel plant-operation versus manufacture. Eng Fail Anal ,
2000, 7(1), p55~67.
[6] V. J. Colangelo and F. A. Heiser , Analysis of Metallurgical
Failures , John Wiley & Sons , N.Y. , 1989, p156~158 ,
p214~219.
[7] H. R. Herz , ,Miscellaneous Papers , Macmillan , 1986.
[8] E. Rabinowicz ,,Friction and Wear of Materials , John Wiley &
Sons , N.Y. , 1965, p113.
[9] M. A. Meyers and K. K. Chawla , Mechanical Metallurgy -
principles and applications , Prentice-Hall , New Jersey , 1984,
p612~614.
[10] R. A. Bareiss , Determination of Residual Stresses by Identation
Methods , WADC Tech. Rep. , Wright-Patterson Air Force Base ,
Ohio , p54~615 , 1954 , Dec.
[11] George F. Vander Voort , Metallography-Principles and Practice
, McGraw-Hill , 1984 , p396.
[12] E.R. Petty , Techniques of Metals Research , Vol.5 , Pt. 2 , R. F.
Bunshah , Wiley-Interscience , N. Y. , 1971, p157.