Casting material for indefinite rollers with a sleeve part and method for producing the same

Abstract

A method for the production and processing of alloyed casting material for a working part of an indefinite chill roll, a corresponding casting material and a composite indefinite chill roll incorporating the casting material. The method comprises providing a melt of a certain composition, casting the melt and subjecting the resultant body to a heat treatment. The composition of the melt is adjusted so as to afford a certain graphite and carbide distribution.

What is claimed is:  
     
         1 . A casting material for the working area of indefinite chill rolls comprising an alloy of, in wt-%, 
 2.0 to 3.5 carbon    1.0 to 2.0 silicon    0.5 to 2.0 manganese    1.0 to 3.0 chromium    3.5 to 4.9 nickel    0.20 to 2.9 molybdenum    0 to 0.65 aluminum and    more than 0.5 to 5.9 vanadium, provided that the vanadium may in part be replaced, in an amount of less than 0.6 wt-%, by at least one of niobium and tantalum, the remainder being iron, accompanying elements and impurities related to the manufacturing process, wherein 1.0 to 3.0 vol-% of graphite is present in the form of particles with a distribution of more than 20 and less than 100 particles per mm 2  of polished surface of the alloy.    
     
     
         2 . The casting material of  claim 1 , wherein the alloy comprises 1.8 to 4.9 wt-% of vanadium and 2.2 to 3.1 wt-% of carbon, and wherein 1.2 to 2.5 vol-% of graphite is present in the form of particles with a distribution of more than 22 and less than 90 particles per mm 2  of polished surface.  
     
     
         3 . The casting material of  claim 2 , wherein the alloy comprises, in wt-%, 1.2 to 2.5 chromium, 0.5 to 2.1 molybdenum and 1.5 to 4.9 vanadium.  
     
     
         4 . The casting material of  claim 1 , wherein a concentration ratio of carbon to silicon in the alloy is not higher than 2.6.  
     
     
         5 . The casting material of  claim 3 , wherein a concentration ratio of carbon to silicon in the alloy is not higher than 2.0.  
     
     
         6 . The casting material of  claim 4 , wherein the alloy comprises 2.6 to 2.95 wt-% of carbon.  
     
     
         7 . The casting material of  claim 6 , wherein the alloy comprises 1.2 to 1.85 wt-% of silicon.  
     
     
         8 . The casting material of  claim 5 , wherein the alloy comprises 1.4 to 1.75 wt-% of silicon.  
     
     
         9 . The casting material of  claim 8 , wherein the alloy comprises 0.002 to 0.65 wt-% of aluminum.  
     
     
         10 . The casting material of  claim 7 , wherein the alloy comprises 0.005 to 0.04 wt-% of aluminum.  
     
     
         11 . The casting material of  claim 4 , wherein the alloy comprises 3.5 to 4.7 wt-% of nickel.  
     
     
         12 . The casting material of  claim 5 , wherein the alloy comprises 4.15 to 4.6 wt-% of nickel.  
     
     
         13 . The casting material of  claim 6 , wherein a concentration ratio of molybdenum to chromium in the alloy is less than 1.0.  
     
     
         14 . The casting material of  claim 7 , wherein a concentration ratio of molybdenum to chromium in the alloy is less than 0.8.  
     
     
         15 . The casting material of  claim 1 , wherein the alloy comprises 1.5 to 2.01 wt-% of chromium and 0.3 to 0.9 wt-% of molybdenum.  
     
     
         16 . The casting material of  claim 15 , wherein the alloy comprises 1.8 to 3.9 wt-% of vanadium.  
     
     
         17 . The casting material of  claim 10 , wherein the alloy comprises 1.9 to 2.95 wt-% of vanadium.  
     
     
         18 . The casting material of  claim 4 , wherein the material comprises 8 to 35 vol-% of eutectic carbides and 1 to 15 vol-% of carbides of at least one of vanadium, niobium and tantalum.  
     
     
         19 . The casting material of  claim 18 , wherein the material comprises 10 to 25 vol-% of eutectic carbides.  
     
     
         20 . The casting material of  claim 18 , wherein the material comprises 2 to 10 vol-% of carbides of at least one of vanadium, niobium and tantalum.  
     
     
         21 . A composite indefinite chill roll comprising a core part and a working or sleeve part surrounding the core part, wherein the core part is made of low-alloy cast iron and the working or sleeve part has a thickness of 10 to 150 mm and is made of a casting alloy with little tendency to adhere or weld to the rolling stock, has a Shore C hardness of 70 to 90 and comprises 1.0 to 2.5 vol-% of graphite, the latter being finely dispersed with a graphite particle count of more than 20 particles per mm 2  of polished surface in a metallographic section, 8 to 35 vol-% of eutectic carbides, and 1 to 20 vol-% of uniformly distributed carbides of at least one of vanadium, niobium and tantalum, with the remainder primarily composed of martensite and constituents related to impurities and the manufacturing process.  
     
     
         22 . The composite indefinite chill roll of  claim 21 , wherein the working or sleeve part comprises 1.0 to 2.5 vol-% of graphite, the latter with a graphite particle count of at least 22 but less than 100 graphite particles per mm 2  of polished surface, 10 to 25 vol-% of eutectic carbides and 2 to 10 vol-% of carbides of at least one of vanadium, niobium and tantalum.  
     
     
         23 . The composite indefinite chill roll of  claim 22 , wherein the casting alloy of the working or sleeve part comprises, in wt-%, 
 2.0 to 3.5 carbon    1.0 to 2.0 silicon    0.5 to 2.0 manganese    1.0 to 3.0 chromium    3.5 to 4.9 nickel    0.20 to 2.9 molybdenum    0.002 to 0.65 aluminum and    0.5 to 5.9 vanadium, provided that the vanadium may in part be replaced, in an amount of less than 0.6 wt-%, by at least one of niobium and tantalum, with the remainder being iron and impurities.    
     
     
         24 . The composite indefinite chill roll of  claim 23 , wherein the casting alloy of theworking or sleeve part comprises, in wt-%, 
 2.21to3.1 carbon    1.2 to 1.85 silicon    0.6 to 1.6 manganese    3.5 to4.7 nickel    0.005 to 0.1 aluminum and    1.8 to 3.9 vanadium.    
     
     
         25 . The composite indefinite chill roll of  claim 24 , wherein the casting alloy of the working or sleeve part comprises, in wt-%, 
 2.6 to 2.95 carbon    1.4 to 1.75 silicon    0.7 to 1.4 manganese    1.5 to 2.01 chromium    4.15 to 4.6 nickel    0.3 to 0.9 molybdenum    0.005 to 0.04 aluminum and    1.9 to 2.9 vanadium.    
     
     
         26 . The composite indefinite chill roll of  claim 23 , wherein the casting alloy of the working or sleeve part comprises 3.1 to 3.9 wt-% of vanadium.  
     
     
         27 . The composite indefinite chill roll of  claim 26 , wherein the casting alloy of the working or sleeve part comprises 3.3 to 3.75 wt-% of vanadium.  
     
     
         28 . The composite indefinite chill roll of  claim 21 , wherein the core part is made of ductile iron.  
     
     
         29 . The composite indefinite chill roll of  claim 28 , wherein a binding zone between the working or sleeve part and the core part has, in the radial direction, a bending strength (3-point bending test) of greater than 600 N/mm 2 .  
     
     
         30 . A casting material for the working area of indefinite chill rolls comprising an alloy of, in wt-%, 
 2.21 to 3.1 carbon    >1.2 to 1.85 silicon    0.6 to 1.6 manganese    1.3 to 2.5 chromium    3.5 to 4.7 nickel    0.25 to 1.3 molybdenum    0 to 0.1 aluminum    1.8 to 3.9 vanadium, and optionally, less than 0.6 wt-% of at least one of niobium and tantalum, the remainder being iron, accompanying elements and impurities related to the manufacturing process, wherein 1.0 to 3.0 vol-% of graphite is present in the form of particles with a distribution of more than 20 and less than 100 particles per mm 2  of polished surface of the alloy.    
     
     
         31 . The casting material of  claim 30 , wherein the alloy comprises, in wt-%, 
 2.6 to 2.95 carbon    1.4 to 1.75 silicon    0.7 to 1.4 manganese    1.5 to 2.01 chromium    4.15 to 4.6 nickel    0.3 to 0.9 molybdenum    0 to 0.04 aluminum and    1.9 to 2.9 vanadium.    
     
     
         32 . The casting material of  claim 31 , wherein 1.2 to 2.5 vol-% of graphite is present in the form of particles with a distribution of more than 22 and less than 90 particles per mm 2  of polished surface.  
     
     
         33 . The casting material of  claim 32 , wherein the material comprises 8 to 35 vol-% of eutectic carbides and 1 to 15 vol-% of carbides of at least one of vanadium, niobium and tantalum.  
     
     
         34 . The casting material of  claim 33 , wherein the material comprises 10 to 25 vol-% of eutectic carbides.  
     
     
         35 . The casting material of  claim 34 , wherein the material comprises 2 to 10 vol-% of carbides of at least one of vanadium, niobium and tantalum.  
     
     
         36 . The casting material of  claim 35 , wherein a concentration ratio of carbon to silicon in the alloy is not higher than 2.0.  
     
     
         37 . The casting material of  claim 36 , wherein a concentration ratio of molybdenum to chromium in the alloy is less than 0.8.