Toolox steel mill applications

Applications In Steel Mill

HE-C

K 13

0527

Benefits Of Selecting Toolox

✔ Ready to use – no heat treatment required✔ Easy to machine✔ Weldable✔ Possible to gas cut✔ Perfect for nitriding✔ Dimensional stability✔ Wear resistance – even high temperatures✔ Crack resistance

Metallurgy

Sliding Shoe

PRESSURE POLE

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High production cost

Olov Zakrisson - Area Technical Manager

25mm Hardox 400 provides 2 months of servicelife

HX400%Plateprice%Euro%/%ton% 1%500%€%Ext.%forma;ng%cost%/%ton% 2%100%€%Servicelife%/%ton% 360%days%Total'cost'/'day'' 10,0'€'Cost'exkl.'forma9ng' 4,2'€''

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Due to the high bendingforce needed external bending capacity must be obtained, rendering a high formating cost.

Sliding Shoe

Sliding ShoeDESCRIPTION

Sliding shoe of pressure pole in coking plant.Pushes ready coke out of the blast furnace oven.Abrasion due to sliding on hot coke on top of a bed of heat resistant bricks.

Surrounding temperatures of approximately 1050 °C.Shoe is at temperatures of around 500 °C. Stays in oven 60 seconds per push.

Hardox 400 at 25 mm ⫤ 2 MONTHS

PROBLEMS

High temperature ruins hardness.After service life below 250 HB.

Expensive formatting.Require extreme bending forces.

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High production cost

Olov Zakrisson - Area Technical Manager

25mm Hardox 400 provides 2 months of servicelife

HX400%Plateprice%Euro%/%ton% 1%500%€%Ext.%forma;ng%cost%/%ton% 2%100%€%Servicelife%/%ton% 360%days%Total'cost'/'day'' 10,0'€'Cost'exkl.'forma9ng' 4,2'€''

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HX400

Cost /&day

Due to the high bendingforce needed external bending capacity must be obtained, rendering a high formating cost.

Sliding Shoe

What about Toolox?

➠ Toolox 44 ⫤ 8 MONTHS

EXPERIENCE

Longer service life.Will not back-temper at 500 °C.Less maintenance, less downtime.

Lower formatting costs.

Hardness HBW410 - 475

Impact toughness Test temperature20 °C

Impact energy, Charpy-V-test for plate, transverse direction; min J ≤ 130 mm 18

Impact energy, Charpy-V-test forforged bar, thickness direction; min J> 130 mm 11

Ultrasonic inspection Ultrasonic inspection is carried out according to:EN 10 160 (rolled plates)EN 10228-3 (forged bars)with extra demands according to specification SSAB V6

Etching Toolox 44 fulfils the etching requirements of NADCA # 207-2006.

Dimensions Toolox 44 is supplied as plate in thicknesses between 5 - 130 mm, or as forged bars in thicknesses between 150 - 300 mm.

Delivery condition Quenched and tempered at a minimum temperature of 590 ˚C.

Heat treatment Toolox 44 is not intended for further heat treatment. If Toolox 44 is heated above590˚C after delivery from SSAB Plate no guarantees for the properties of the steel are given.

Nitriding/coating Nitriding or surface coating may be carried out if the temperature is below 590 °C.

Testing Testing according to EN 10 025 and EN ISO 6506-1.Hardness is measured on a milled surface 0.5 - 2 mm below the original surface.

Tolerances Thickness, length, width and flatness tolerances according to “Dimension program andtolerances for new rolling of tool steel plates from SSAB Plate”.Forged bars; According to DIN 7527.

Surface finish On delivery from SSAB Plate the plate meets the following specifications: - free from mill scale - not repair welded - surface defects below the nominal ordered thickness are not permitted.Forged bars according to DIN 7527.

Product sheet: Toolox® 44, 450 HBW (~45 HRC) with ESR properties

Specification

200

9-0

9-20

SSAB Oxelösund AB SE-613 80 Oxelösund Sweden

Tel: +46 155 25 40 00 Fax: +46 155 25 55 34 [email protected] www.toolox.com

Hardness HBW410 - 475

Impact toughness Test temperature20 °C

Impact energy, Charpy-V-test for plate, transverse direction; min J ≤ 130 mm 18

Impact energy, Charpy-V-test forforged bar, thickness direction; min J> 130 mm 11

Ultrasonic inspection Ultrasonic inspection is carried out according to:EN 10 160 (rolled plates)EN 10228-3 (forged bars)with extra demands according to specification SSAB V6

Etching Toolox 44 fulfils the etching requirements of NADCA # 207-2006.

Dimensions Toolox 44 is supplied as plate in thicknesses between 5 - 130 mm, or as forged bars in thicknesses between 150 - 300 mm.

Delivery condition Quenched and tempered at a minimum temperature of 590 ˚C.

Heat treatment Toolox 44 is not intended for further heat treatment. If Toolox 44 is heated above590˚C after delivery from SSAB Plate no guarantees for the properties of the steel are given.

Nitriding/coating Nitriding or surface coating may be carried out if the temperature is below 590 °C.

Testing Testing according to EN 10 025 and EN ISO 6506-1.Hardness is measured on a milled surface 0.5 - 2 mm below the original surface.

Tolerances Thickness, length, width and flatness tolerances according to “Dimension program andtolerances for new rolling of tool steel plates from SSAB Plate”.Forged bars; According to DIN 7527.

Surface finish On delivery from SSAB Plate the plate meets the following specifications: - free from mill scale - not repair welded - surface defects below the nominal ordered thickness are not permitted.Forged bars according to DIN 7527.

Product sheet: Toolox® 44, 450 HBW (~45 HRC) with ESR properties

Specification

200

9-0

9-20

SSAB Oxelösund AB SE-613 80 Oxelösund Sweden

Tel: +46 155 25 40 00 Fax: +46 155 25 55 34 [email protected] www.toolox.com

Cable Drum

Cable DrumDESCRIPTION

Cable drum used for a wagon in coking plant

➠ Toolox 44EXPERIENCE

220 mm forged block machined with HSS tools to 190 mm.Combination of strength, hardness, and toughness very important.Works perfectly since 2010.

Slag Bucket

Slag BucketDESCRIPTION

Bucket for handling hot slag.Temperatures up to 1500 °C.

Hardox 400, St52, Heat Resistant Steel ⫤ 8 WEEKS➠ Toolox 33 ⫤ 8 MONTHS

EXPERIENCE

Toolox offers high temperature wear resistance.Reflected in much longer lifetime of Toolox.

Installed January 2011Photo Taken April 19 2011

Crane Wheel

Crane WheelDESCRIPTION

Steering wheel in an overhead crane⌀ 610 mm L 125 mm

35CrNiMo14 INDUCTION HARDENED ➠ Toolox 44EXPERIENCE

Faster manufacturing.Water jet cut and directly machined to final piece.

Safer solution due to no heat treatment.Critical component.

First test in 2006 and introduced as standard.Wheels typically replaced every 3-4 years.

Steering Wheel

Steering WheelDESCRIPTION

Steering wheel in an overhead crane⌀ 250 mm L 86 mm

1.6582 / 34CrNiMo6 ➠ Toolox 44EXPERIENCE

Hardness consistent across material.Crack problems due to hardening avoided.No heat treatment shortens lead time

1.6582 bar – Turn, thread, harden, and machine again.Toolox – Gas cut, turn, thread.

Steering wheel and crane wheel used in 10-15 similar applications.

Bearing House

Bearing HouseDESCRIPTION

Bearing house for rollers in continuous caster⌀ 230 mm L 60 mmCorrosion and cyclic thermal load


Increased lifetime from 6 months to at least 1 year.Easily gas cut and machined.Rollers surface welded with stainless steel electrodes to protect against corrosion.Since 2006 standard for this application.

Support Beams

Support BeamsDESCRIPTION

Support beams for rollers in continuous casterAll materials pass through continuous caster.

1900 x 200 x 40 mm

➠ Toolox 33 NITRIDED

EXPERIENCE

Machine easily and to close tolerances.Black nitriding to resist wear and corrosion.High quality control and guaranteed properties.

Very important in this sensitive application.Since 2010 solution introduced as standard.More than 125 pieces manufactured.

Rolling Mill

Slide Rails

Slide RailsDESCRIPTION

Slide rails to guide and move rollersRollers slide on rails when moved for regrinding.Each roller weighs 40-50 tonnes.

Lengths up to 2500 mmThicknesses 30, 50.7, 86 mm

1.7225 / 42CrMo4 ➠ Toolox 33 NITRIDED

EXPERIENCE

Excellent flatness and dimensional stability.Black nitriding to resist wear and corrosion.64 rails produced, total length 121.7 m.Rails installed 2009, since then running perfectly.

Step Plate

Step PlateDESCRIPTION

Step plate to adjust height of rollers in mill1199 x 850 x 210 mm, 1199 x 1050 x 150 mm

1.6582 INDUCTION HARDENED, 1.2738 HH➠ Toolox 33EXPERIENCE

Require high strength and toughness.1.6582 low strength.1.2728 HH cracked as well as Toolox 44.

Forged Toolox cut then machined to final pieceThicker piece gas cut. Thinner piece waterjet cut.

Rocker Plate

Rocker PlateDESCRIPTION

Base plate to support HGC hydraulic cylinderSits on top of step plate in rolling mill.

2020 x 1490 x 110 mmRequire very good flatness.

St52-3 / 1.0570 ➠ Toolox 33EXPERIENCE

Machining and welding strips at edges.Dimensional stability and precision allowed for faster manufacturing.Replaced every 2-3 years due to corrosionand wear.

Sleeve Bushing

Sleeve BushingDESCRIPTION

Sleeve to cover cracked rollers.Replacement roller took over a month to deliver.

Rollers ⌀ 950 mm L 1087 mmSleeve ⌀ 950 mm L 300 mm

17CrNiMo6 CASE HARDENING ➠ Toolox 33EXPERIENCE

2 rings of thickness 165 mm usedCut, bent, welded, and crimped onto rollerProduction downtime minimized whilewaiting for replacement roller.

Gear Rack

Gear RackDESCRIPTION

Gear rack in rolling millSits on ruler arms to guide and center the plates.

2614 x 210 x 66 mm

1.7225 / 42CrMo4 V ➠ Toolox 33EXPERIENCE

Gas cut 70 mm plate and machined.Very happy due to fast machining andhigh dimensional stability.Since 2007 introduced as standard.Gear racks replaced every 2-3 years due to corrosion and wear.

Wear Protection Plate

Wear Protection PlateDESCRIPTION

Wear protection plate in four-high rolling mill.Used in several different positions.

Dimension Example 1285 x 1000 x 38 mmDemanding operating conditions.

Sliding forces when rolls lowered towards steel, with 1 million cycles per year.Corrosive atmosphere with grease, scale and water.

Previous material uneconomical to produce, risk of cracks, long delivery time.

Compound Plate (Soft / 60 HRC) ➠ Toolox 44 NITRIDED

Wear Protection Plate

Compound Plate (Soft / 60 HRC) ➠ Toolox 44 NITRIDED

EXPERIENCE

More economical productionGas cut 43 mm, machined, black nitrided.

Good performance.Hardness 64-71 HRC ensures wear resistance.Black nitriding also ensures corrosion resistance.Toughness of Toolox ensures crack resistance.

Introduced in 2003 and now standard for over 40 similar wear pieces.

Some positions corrosion and deformation still play a role, but Toolox 44 the best solution for the application.

Chain Gear

Chain GearDESCRIPTION

Chain gear in steel plate conveyorConveyor driving steel plates into a heating furnace.

Previously one piece milled from ⌀ 380 mm round.80% material waste.

1.7218 / 25CrMo4 ➠ Toolox 44EXPERIENCE

New design gives less material cost.Collar in mild steel.Gears in Toolox ⌀ 368 mm L 174 mm

Much longer lifetime.

WedgeDESCRIPTION

Wedges to optimize space between shear blades. 4600 x 170 x 70 mm

Require high flatness and precise tolerances.

1.6582, C45 ➠ Toolox 33EXPERIENCE

Easier machining due dimensional stability.Water cut 84 mm plate, machined, put in use.

Toolox 33 now used as standard for this solution.

Knife Support

Knife SupportDESCRIPTION

Knife support for steel plate shear in rolling mill.4000 x 230 x 80 mm

Require flatness of 0.1 mm over 4000 mm.Failure due to plastic deformation after 1 year.

1.7218 / 25CrMo4 ➠ Toolox 33EXPERIENCE

Manufacturing much faster.Previous material milled both sides from 104 mm.Toolox milled from one side only.

Support now replaced intervals of 2-3 years.Toolox now the standard for this application.

Shear Blade

Shear BladeDESCRIPTION

Shear blade to cut Hardox / Weldox steel plates.Used in different cutting machines.

Dimension Example 3700 x 200 x 70 mm

1.2767 HT 50 HRC ➠ Toolox 44 NITRIDED

Shear Blade

1.2767 HT 50 HRC ➠ Toolox 44 NITRIDED

EXPERIENCE

Each corner used until worn out.8000 cuts / corner and a life of one month.Knife rotated so all 4 corners used.Then short edges of knife remachined and knife put back in use. No need for re-nitriding.

Superior performanceHigh strength and wear resistance.Nitriding layer prevents debris sticking to surface

Cutting Blade

Cutting BladeDESCRIPTION

Blades for cutting plates in rolling mill.300 x 48 x 16 mm


EXPERIENCE

Gas cut, machined, nitrided.Low manufacturing cost for each blade.

Hydraulic Cylinder Base

Hydraulic Cylinder BaseDESCRIPTION

⌀ 292 mm L 99 mm

1.6582 / 34CrNiMo6 ➠ Toolox 33EXPERIENCE

104 mm gas cut, treated, machined to final piece.Advantages homogeneity and shape stability

Very important in hydraulic components.

Bearing House

Bearing HouseDESCRIPTION

Bearing house for plate leveler320 x 210 x 110 mmThin walls around bearing

1.7218 / GS25CrMo4 VII ➠ Toolox 33EXPERIENCE

Gas cut Toolox and machined to final piece.Meets dimensional stability requirement in machining.Bearing houses changed typically every 1-2 years.Since 2007 standard in several similar machines.

Finishing & Testing

Wheel Hub

Wheel HubDESCRIPTION

Wheel hub for heavy duty trucksHigh forces on the hub with loads up to 40 tonnes.⌀ 773 mm L 317 mmReplacement hubs take 3 months delivery

Cast Material ➠ Toolox 33EXPERIENCE

In-house manufacturing possible3 rings from 130 mm cut, welded, machined.

Works perfectly since 2007.

Brake Disc

Brake DiscDESCRIPTION

Brake disc of large slag transport truck8 discs on each truck.Elevated temperature during braking.

~ ⌀ 500 mm


High temperature propertiesFaster delivery, lower cost.

Discs produced from plates.Cost saving of 550 euro / disc

Increased toughness.

Rotation Bar

Rotation BarDESCRIPTION

Rotation bar in slag transport truck.2 bars on each truck.

~ ⌀ 300 mm

240 HB Material ➠ Toolox 44EXPERIENCE

Longer lifetime.Previously failure due to wear.Higher strength, hardness, toughness.

Forged bar 300 mm of Toolox used.

Axles & Axle Trees

Axles & Axle TreesDESCRIPTION

Axle and axle trees used in slag transport truck.

42CrMo4 / 1.7225 ➠ Toolox 44EXPERIENCE

Axles made from ⌀ 280 mm bars.Axle trees hard-face welded and milled.Less wear than previous solution.Running since 2010.

Sprocket Wheels

Sprocket WheelsDESCRIPTION

Sprocket wheels in steel plate painting line.Wheels are scrapped when the teeth are worn out.⌀ 680 mm L 180 mm

C 45 ➠ Toolox 33EXPERIENCE

Triplex pinion was made with 3 plates of 80 mm gas cut and machined.Avoided long delivery time of cast material.Better lifetime and high reliability.Running since 2006.

Shot Blasting Ramp

Shot Blasting RampDESCRIPTION

Shot blasting ramp in de-scaling system.Water nozzles are positioned in the holes.

Entire ramp previously made from cast material.


New design gives much longer life.Toolox in most worn part of ramp3770 mm x 250 mm x 70 mm

Flatness requirement and precise tolerances.Easy maintenance with removable part.First time installed 2008, remade in 2013.

Pinion

PinionDESCRIPTION

Pinion in cutting machineDriving cutting machine by running against gear rack.⌀ 80 mm L 61 mm

1.6582 / 34CrNiMo6 NITRIDED ➠ Toolox 33 NITRIDED

EXPERIENCE

Gas cut 70 mm plate, machined, nitrided.Performing perfectly since 2006.

Saw Support

Saw SupportDESCRIPTION

Support sitting behind circular saw.710 x 100 x 40 mmPrevious material short lifetime and difficult to achieve small tolerances in manufacturing.


EXPERIENCE

43 mm gas cut, machined, nitrided.In use since 2006 with perfect result.

Boring Tool Support

Boring Tool SupportDESCRIPTION

Tool support for boring large holes.Holes up to 1000 mm diameter.

Method gives closer tolerances and better surfaces than normal milling.Used Toolox due to availability.


Component meets dimensional requirements.Good result in usage.

Machine Frame

Machine FrameDESCRIPTION

Machine frame of tensile testing equipment.On average 700 specimens tested weekly.Maximum load force reaches up to 95 ton.

C45 HARDENED, St52-2 ➠ Toolox 33EXPERIENCE

Easy machining.Much longer service life.

No cracking as compared to C45. More resistant to deformations as compared to St52.Sliding surface deformed only 5/100 mm in Toolox frame after 1 year vs 16/100 mm in St52 after failure.

VicesDESCRIPTION

Vices to clamp specimen in tensile testing.Previous material failure due to cracking and wear.

1.2358 HT 55 HRC + NITRIDED ➠ Toolox 44 NITRIDED

EXPERIENCE

First test with Toolox 33.Low lifetime due to plastic deformation.

Toolox 44 machined, textured, nitrided.Much longer service life.

1.2358 need 24-28 pieces annually.Toolox 44 need 6-8 pieces annually.

Hydraulic Cylinder

Hydraulic CylinderDESCRIPTION

Hydraulic cylinder in tensile testing machine.Push shoes locking the steel test specimens.Found in both upper and lower part of machine.

High demands on cylinders.Extreme and repetitive forces.

C60, C45 HT 63 HRC ➠ Toolox 44 NITRIDED

EXPERIENCE

Milled, turned, grinded, nitrided.Since 2005 working perfectly.

Failure of regular C60 due to low strength.Failure of heat treated C45 due to cracking.

Tensile Jaw

Tensile JawDESCRIPTION

Tensile jaws in in tensile testing machineStrong material needed due to high forces


EXPERIENCE

Machined, textured, nitrided.Longer lifetime than original material.

Fixture

FixtureDESCRIPTION

Fixture used to hold and prepare samples.Strong and tough material required.

Guarantee tolerances and avoid cracks.


EXPERIENCE

Gas cut, machined, nitrided.Works perfectly since 2007.

Fixture

FixtureDESCRIPTION

Fixture to clamp work-piece in circular saw100 x 30 x 17.3 mm

1.2311 NITRIDED, Hardox 500 ➠ Toolox 44 NITRIDED

EXPERIENCE

Gas cut, strips sawed, machined and nitrided.In operation since 2007 with perfect result.

Rail Connection

Rail ConnectionDESCRIPTION

Rail connection in harbour crane.Every crane wheel pass local deformation.

1000 cycles / day.Previous material lifetime one year.

St52-3 / 1.0570 ➠ Toolox 33EXPERIENCE

70 mm plate cut and machined.Much longer lifetime.

Now can replace rail and connection at same time.

Toolox steel mill applications

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