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In the steel industry, the equipment reliability and performance add much to sustaining the production flow efficiently. There is little doubt that the backup roll is one such integral component that plays really a vital role in this regard. It supports the rolls in the milling process. Given that these rolls undergo high pressures, abrasion, and thermal cycling, it is essential to keep re-grinding them up to scrap dia as recommended by OEMS, however being an expensive component steel mills were always looking forward to salvage such rolls by restoring their lost thickness fully or partially to take reduce the cost of their inventory and now the technique and suitable alloys are available to weld-clad them with wear resistant materials time to time.
There are only few countries were Back rolls have been successfully repaired for Example Germany ,Turkey, Chaina and in India ,same services will be available through TNA (Tarek Nasser Al Akeel) Service welding Division in Saud Arabia.
The backup rolls in steel mills have several vital functions:
They constitute the major rolls, supporting stability so that everything is kept in line and in perfect balance when milling takes place.
Load Bearing: Reserve rolls gobble up a lot of the fighting forces themselves, thus leaving the actual main rolls performing at their best.
The backup rolls are very crucial, and maintaining them in good condition is important for the general efficiency of the steel production process.
Backup rolls face various challenges that can lead to wear and damage:
Abrasion: Repeated contact of abrasive materials removes the surfaces of the material.
Fatigue: Microcracks may develop by repeated loading and unloading cycles and eventually could be the failure mechanism.
Thermal Stress: It undergoes thermal fatigue and warping because of the overheating condition during operation.
At Tarek Nasser Al Akeel Co. (TNA), we have developed a systematic approach to repairing backup rolls that ensures high-quality results:
We have always repaired backup rolls systematically at TNA and are given the full satisfaction of completeness and quality with guaranteed efficacy.
1. Inspection and Appraisal: Inspect each roll for wear pattern, cracks, and damage. We can also use some sophisticated methods such as ultrasonic testing to identify subsurface damage.
Surface preparation involves making the damaged area clean and ready for welding. This mainly grinds or machines, hence eliminating all form of contamination while creating a good solid bond.
3. Weld Repair Application: In the process of repairing, we apply various welding techniques as per the need requirement.
TIG (Tungsten Inert Gas) Welding: Ideal for intricate repairs that require precision.
MIG (Metal Inert Gas) Welding: Suitable for larger areas, providing a strong bond with faster deposition rates.
Flux-Cored Arc Welding (FCAW): Effective in high-abrasion environments, delivering excellent mechanical properties.
4. PWHT: After welding is performed, we can use post weld heat treatment of the rolls where residual stresses get relieved, and properties are maximized in that particular area.
5. Inspection and Machining Rolled over carries are inspected for conformance to specification. As a requirement to restore the original dimensions and surface finishes, it should be machined based on necessity.
Opting for TNA for your weld repair needs brings you a range of key benefits:
Extended Service Life: Our specialized techniques help to significantly increase the lifespan of your backup rolls, minimizing the frequency and cost of replacements.
Cost Saving: The services reduce downtime and the cost of repair, thus saving the costs for the steel companies.
Improved Performance: Re-rolled rolls ensure solid structural integrity and hence a quality product in terms of consistency and effectiveness.
Expertise and Quality Assurance: The best welding technologies are equipped by our skilled technicians along with quality checks for proper repair.
Weld repairs on backup rolls are key to boosting both productivity and product quality in steel plants at the same time can result in huge cost saving in production. At Tarek Nasser Al Akeel Co. (TNA), we focus on strengthening the durability and efficiency of your rolls to keep your production running at it’s best. We can repair/restore up to 40-50 mm on diameter by suitable Cr-Mo composition alloys providing almost equivalent service life .
The enclose graph shows the wear pattern of cast, forged and welded rolls in the production cycle of 100,000 MT. It is evident that welded rolls gets worn only by ¼ time as compared to cast and forged Back up rolls By partnering with us, you’ll enjoy reduced costs, longer equipment life, and a smoother operation overall. Want to learn how we can help? Reach out to TNA anytime—we’re here when you need us.