Overview
50% WC slotted roller; delamination occurred in the slotted area After removing the entire slotted section, the roller was restored using hardfacing repair
Industry
Steel
Location
Chiba City / Chiba prefecture, JP
Component/Workpiece
KVM195 Mill Roller
Business Type
Integra - Workshop
Job Type
Repair
OEM
Kawasaki Heavy Industries, Ltd.
Type of Wear
Base Metal
A105N
General Dimensions (mm)
OD1440mm x ID900×H535mm
The challenge the customer was facing
Traditionally, manufacturers have used expensive slit rollers that cannot be remanufactured; as delamination occurred during operation, leading to a reduction in shredding efficiency, customers have raised doubts about the cost-effectiveness of this type of roller.
Previous Service Life
3y
How WA solved the challenge
① Removal of the WC slit area by gouging ② Partial repair of the delaminated areas and areas where the material has been gouged out using a bimetallic welding material ③ Hardfacing (309L (t2.5) + 307 (t2.5) + HC-O (t8) + VN-O (t20)) ④ PWHT (550°C × 3 hours)
Product Category
Integra Services
Product Description
HC-O 2.8mm / VN-O 2.8mm
Technical Advantages
Compared to WC slit rollers, this option carries a lower risk of delamination and is recyclable. It also offers the advantage of being more cost-effective than purchasing new rollers. Given the expected volatility in tungsten prices, this proposal is anticipated to become increasingly advantageous.
Photos and visuals for this case study
Annual Cost Before
€0.00
Annual Cost After
€0.00
Annual Savings
€0.00
0.0% reduction
Annual Cost = (A × E) + (E − 1) × (F + G + H)
Where: A = Cost of Part, E = Parts/Year, F = Maintenance, G = Disassembly, H = Downtime
No WPS data available for this case study
Contributor
Takanori Sasaki
takanori.sasaki@waj.co.jp
Created
April 30, 2026
Submitted
April 30, 2026
Approved By
Bastien Gerard
May 3, 2026