Caster roller ø260x969,5 & 1472,5 trial #4

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 #4

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 #4 of 5, where we suggest cladding the rollers with: 1st layer: Chromecore 434N-S 2nd layer: Chromecore 414NX-S 3rd layer: Chromecore 414NX-S

Product Category

Integra Services

Product Description

Manufacturing of cladded continious caster rollers ø260, trial #4

Job Duration

6mo

Technical Advantages

The N-content helps reducing the Cr decrease in the interbeed area, resulting in less interbeed corrosion. 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

€18,003.33

Annual Savings

€7,726.67

30.0% reduction

Annual Cost Comparison
Previous Solution€25,730.00
WA Solution€18,003.33

Cost Breakdown

Part Information
Cost of Part (A):€13,740.00
Cost of WA Solution (B):€13,940.00
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 27, 2026

Submitted

April 27, 2026

Approved By

Laslo Ekres

April 27, 2026