High Speed Steel Rolls

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High Speed Steel Rolls

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High Speed Steel Rolls

We at RELIANT EXIM & CONSULTING LLC adopt slot-based casting process, horizontal centrifugal casting process and vertical casting process based on the size of the Rolls. Most small and medium size rolls use horizontal centrifugal casting and for large size rolls we use vertical centrifugal casting process.We utilise 20 Ton & 30 Ton double power inverter intermediate frequency electric stove, 10 Ton, 5 Ton, and 3 Ton intermediate frequency electric stove, 60 Ton Ladle Furnace, 60 Ton VD Furnace and a Vertical Vacuum casting furnace for our casting processes. All furnaces and stoves are equipped with advanced spraying and sand-casting equipment.RELIANT EXIM & CONSULTING LLC implements ISO 9001:2008 standards and adopts computer-aided control technology to ensure a consistent production process, stable product quality, and reliable performance.

Thermal Treatment Equipment

RELIANT EXIM & CONSULTING LLC is equipped with NC resistance-type furnaces, high and low temperature heat treatment furnaces, coating and quenching equipment, open-type differential temperature heat treatment furnaces, and gas baking ovens. All thermal treatment equipment utilizes computer-aided centralized control systems to provide consistent and proportional temperatures for the furnaces and to ensure dependable roll hardness.

Processing Equipment

RELIANT EXIM & CONSULTING LLC processing & machining shop consists of various machining and finishing equipment: CNC Grinding Machines, CNC Lathe Machines, NC Planer Machines, Double Sided Milling Machines, and over 100 dedicated lathes for various rolls of C61250, C61200, C61125, C84180, C8463, C8440, C91250, etc. Our machining shop is equipped with various high precision cutting and processing equipment clubbed with high skilled and experienced work force guaranteeing machining and finishing accuracy of each of our rolls.

Test and Inspection Equipment

RELIANT EXIM & CONSULTING LLC has an established and error proof quality monitoring and inspection system for complete roll manufacturing process starting from raw materials to the finished goods. With high-skilled quality technicians & engineers and use of advanced inspection and test equipment to collect data and process feedback through computerized processes we achieve superior accuracy along each step and defect free final product.

RELIANT EXIM & CONSULTING LLC incorporates a Raw Material Analysis Center, a Quick Analysis Center, and a Physical Test Center to satisfy all quality testing and inspection needs for the roll manufacturing process. Using the above and inline testing for various steps we control error occurrences and early defect identification. We have strong metrics of error prevention and QC check at each stage of the manufacturing process.

RELIANT EXIM & CONSULTING LLC provides advanced measures for performance & quality control and technical research & development.

Our Raw Material Analysis Centre is equipped with a Chemical Analysis Lab, Moulding Sand Testers, Moulding Sand Hardness Metres, Coating Tester, etc.

The Quick Analysis Centre is equipped with the Leco CS230 Carbon-Sulphur Analyzer, Leco TCH Hydrogen, Oxygen Analyzer and Nitrogen Analyzer, Bruker Germany Q8 Direct Reading Spectrometer, and the OBOB GS 1000 Direct-Reading Spectrometer.

The Physical Test Center is equipped with Universal Material Testers, Impact Test Machines, Brinell & Rockwell Hardness Metre, SHIMADZU MNV-2T Metallurgical Phase Microscope, Leica DM2500M Front- View Metallurgical Phase Microscope, DM6000M Metallographic Image Analyzer, SHIMADZU Thermal Dilatometer, JSM-6150-A Scanning Electron Microscope, KK USD12 Ultrasonic Flaw Detector, etc.

Designation of RollsMaterial CodeC %Si %Mn %Ni %Cr %Mo %V %W %
HSSHSS1.50 – 2.200.30 – 1.000.40 – 1.200.00 – 1.503.00 – 8.002.00 – 8.002.00 – 9.000.00 – 2.00
S – HSSS – HSS0.60 – 1.200.80 – 1.500.50 – 1.000.20 – 1.203.00 – 9.002.00 – 5.000.40 – 3.000.00 – 3.00
Designation of RollsMaterial CodeC %Si %Mn %Ni %Cr %Mo %Mg %
CrMo indefinite chilled SG cast iron rollsSG II3.00 - 3.401.40 - 1.900.20 - 0.800.20 - 0.600.20 - 0.60≥ 0.40
NiCrMo indefinite chilled SG cast iron rolls (I)SG IV3.00 - 3.401.40 - 1.900.40 - 0.800.50 - 1.000.20 - 0.600.20 - 0.60≥ 0.40
NiCrMo indefinite chilled SG cast iron rolls (II)SG V3.00 - 3.401.40 - 1.900.40 - 0.801.10 - 2.000.30 - 1.000.20 - 0.60≥ 0.40
Physical Properties
Designation of RollsMaterial CodeBarrel Hardness HSDNeck Hardness HSDTensile Strength Mpa
CrMo indefinite chilled SG cast iron rollsSG II50 - 7035 - 55>320
NiCrMo indefinite chilled SG cast iron rolls (I)SG IV55 - 7035 - 55>320
NiCrMo indefinite chilled SG cast iron rolls (II)SG V60 - 7035 - 55>320
Microstructure
Designation of RollsMaterial CodeMicrostructure
CrMo Indefinite chilled SG cast iron rollsSG IIPearlite + Cementite + Small Graphite
NiCrMo indefinite chilled SG cast iron rolls (I)SG IVPearlite + Cementite + Small Graphite
NiCrMo indefinite chilled SG cast iron rolls (II)SG VFine Pearlite + Cementite + Small Graphite
Application
Designation of RollsMaterial CodeApplication
CrMo indefinite chilled SG cast iron rollsSG IIProfiles, rods, wire, and narrow strip mill thick, in the rolling mill stand
NiCrMo indefinite chilled SG cast iron rolls (I)SG IVProfiles, rods, wire, and narrow strip mill thick, in the rolling mill stand
NiCrMo indefinite chilled SG cast iron rolls (II)SG VProfiles, rods, wire, and narrow strip mill thick, in the rolling mill stand
Scope of supply
Barrel diameter ≤ 1000 mm Barrel length ≤ 3000 mm
Alloy Cast Steel Rolls
Chemical Analysis
Designation of RollsMaterial CodeC %Si %Mn %Ni %Cr %Mo %
Zu60CrMoMnAS600.55 – 0.650.20 – 0.450.90 – 1.200.80 – 1.200.20 – 0.45
Zu60CrMoMnNiAS60 I0.55 – 0.650.20 – 0.600.50 – 1.000.20 – 1.500.80 – 1.200.20 – 0.60
Zu65CrNiMoAS65 I0.60 – 0.700.20 – 0.600.50 – 0.800.20 – 0.500.80 – 1.200.20 – 0.45
Zu70MnAS700.65 – 0.750.20 – 0.450.80 – 1.40
Zu70Mn2AS70 I0.65 – 0.750.20 – 0.451.40 – 1.80
Zu70Mn2MoAS70 II0.65 – 0.750.20 – 0.451.40 – 1.800.20 – 0.45
Zu75CrMoAS750.70 – 0.800.20 – 0.450.60 – 0.900.75 – 1.000.20 – 0.45
Zu75CrNiMnMoAS75 I0.70 – 0.800.20 – 0.700.70 – 1.10≥ 0.200.80 – 1.500.20 – 0.60
Physical Properties
Designation of RollsMaterial CodeBarrel Hardness HSDNeck Hardness HSDTensile Strength Mpa
Zu60CrMoMnAS6035 – 50≤ 45> 650
Zu60CrMoMnNiAS60 I35 – 45≤ 45> 750
Zu65CrNiMoAS65 I35 - 45≤ 45> 750
Zu70MnAS7032 - 42≤ 45> 650
Zu70Mn2AS70 I35 - 45≤ 45> 680
Zu70Mn2MoAS70 II35 - 45≤ 45> 700
Zu75CrMoAS7535 - 50≤ 45> 700
Zu75CrNiMnMoAS75 I35 – 50≤ 45> 800
Microstructure
Microstructure of working layer in the barrel: pearlite or tempered sorbite
Application
Designation of RollsMaterial CodeApplication
Zu60CrMoMnAS60Bar, wire, strip, steel roughing
Zu60CrMoMnNiAS60 IBar, wire, strip, steel roughing
Zu65CrNiMoAS65 IBar, wire, strip, steel roughing
Zu70MnAS70Bar, wire, strip, steel roughing
Zu70Mn2AS70 IBar, wire, strip, steel roughing
Zu70Mn2MoAS70 IIBar, wire, strip, steel roughing
Zu75CrMoAS75Bar, wire, strip, steel rough rolling, narrow steel support rollers
Zu75CrNiMnMoAS75 IBar, wire, strip, steel rough rolling, narrow steel support rollers
Scope of Supply:-Barrel diameter ≤ 1000 mm / Barrel length ≤ 3000 mm
Pearlitic Ductile Cast Iron Rolls
Chemical Analysis
Designation of RollsMaterial CodeC %Si %Mn %Ni %Cr %Mo %Mg %
Pearlitic ductile cast iron roll ISGP I3.00 – 3.401.40 – 1.900.40 – 0.801.50 – 2.000.20 – 0.600.20 – 0.60≥ 0.04
Pearlitic ductile cast iron roll IISGP II3.00 – 3.401.20 – 2.000.40 – 0.802.01 – 2.500.20 – 1.000.20 – 0.60≥ 0.04
Pearlitic ductile cast iron roll IIISGP III3.00 – 3.401.00 – 2.000.40 – 0.802.51 – 3.000.20 – 1.200.20 – 0.60≥ 0.04
Physical Properties
Designation of RollsMaterial CodeBarrel Hardness HSDNeck Hardness HSDTensile strength Mpa
Pearlitic ductile cast iron roll ISGP I45 – 5535 – 55>450
Pearlitic ductile cast iron roll IISGP II55 – 6535 – 55>450
Pearlitic ductile cast iron roll IIISGP III62 – 7235 – 55>450
Microstructure
Designation of RollsMaterial CodeMicrostructure
Pearlitic ductile cast iron roll ISGP IPearlite + Cementite + Small Graphite
Pearlitic ductile cast iron roll IISGP IIPearlite + Cementite + Small Graphite
Pearlitic ductile cast iron roll IIISGP IIIGlobular Pearlite + Carbide + Graphite or small amount of pearlite
+ Bainite + Carbide + Spherical Graphite
Application
Designation of RollsMaterial CodeApplication
Pearlitic ductile cast iron roll ISGP IProfiles, rods, wire and narrow strip mill thick, in the rolling mill stand
Pearlitic ductile cast iron roll IISGP IIProfiles, rods, wire and narrow strip mill thick, in the rolling mill stand
Pearlitic ductile cast iron roll IIISGP IIIProfiles, rods, wire and narrow strip mill thick, in the rolling mill stand
Scope of supply
Barrel diameter ≤ 1000 mm Barrel length ≤ 3000 mm