Caster roller ø260x969,5 & 1472,5 trial #1

Steel • Gent (Sidmar), Belgium

STAR (+4 pts)
APPROVED

Basic Information

Overview

The customer seeks a solution to improve the lifetime of continuous caster rollers, a bit down the caster on the ø260 rollers. The roll life is today ended due to defects arised mainly from interbeed corrosion.

Industry

Steel

Location

Gent (Sidmar), Belgium

Component/Workpiece

Caster roller ø260x969,5 & 1472,5 trial #1

Business Type

Integra - Workshop

Job Type

New

OEM

Danieli

Type of Wear

Abrasion
Corrosion
Interbeed

Base Metal

21CrMoV5.11 (W1.8070)

General Dimensions (mm)

ø260x969,5 & 1472,5, total weight 820kg

Problem Description

The challenge the customer was facing

The roll life is today with OEM spec. cladding approximately 6 month. Customer aims to reach 50% increased lifetime; 9 months operation. Cladding today is; 1st layer 430-S, 2nd layer 414-S, and 3rd layer 414-S But interbeed corrosion results in spaling and diameter loss.

Previous Service Life

6mo

Competitor

Weldclad

Welding Alloys Solution

How WA solved the challenge

The customer has agreed to make a series of trials with different cladding materials. This case is trial #1 of 5, where we suggest cladding the rollers with: 1st layer: Chromecore 434N-S 2nd layer: Chromecore 414DN-S 3rd layer: Chromecore 414DN-S

Product Category

Integra Services

Product Description

Manufacturing of cladded continious caster rollers ø260

Job Duration

6mo

Technical Advantages

The N-content helps reducing the Cr decrease in the interbeed area, resulting in less interbeed corrosion. The carbide content results in better mechanical wear on the roll surface. Target is as mentioned earlier an increased service life of 50%. The 5 different trials will be run parallel, determining the most cost effective solution.

Service Life

9mo

Images (2)

Photos and visuals for this case study

Case study image 1Case study image 2

Cost Reduction Analysis

Annual Cost Before

€25,730.00

Annual Cost After

€18,230.00

Annual Savings

€7,500.00

29.0% reduction

Annual Cost Comparison
Previous Solution€25,730.00
WA Solution€18,230.00

Cost Breakdown

Part Information
Cost of Part (A):€13,740.00
Cost of WA Solution (B):€14,110.00
Parts Used/Year (E):2
Solution Lifetime Comparison
Previous Solution:6.1 months
WA Solution:9.1 months
WA solution lasts 1.5x longer!
Before (Previous Solution)
Maintenance/Repair (F):€-600.00
Disassembly Cost (G):€-150.00
Downtime/Event (H):€-1,000.00
After (WA Solution)
Maintenance/Repair (F):€-600.00
Disassembly Cost (G):€-150.00
Downtime/Event (H):€-1,000.00
Formula Used

Annual Cost = (A × E) + (E − 1) × (F + G + H)

Where: A = Cost of Part, E = Parts/Year, F = Maintenance, G = Disassembly, H = Downtime

Additional Benefits

Environmental impact, less downtime. Increased productivity.

Welding Procedure Specification (WPS)

3 layer(s) documented

Submission Details

Contributor

Henrik Stigers

henrik.stigers@dalforsan.se

Created

April 24, 2026

Submitted

April 24, 2026

Approved By

Laslo Ekres

April 26, 2026