WHEMCO Inc.

The Largest Rollmaker in USA

HISTORY

PARK CORPORATION• Whemco Inc. Owners: PARK CORPORATION

• Private US company: – Financially rated: “Strong”

– Dunn & Brad Street rating: 5A1 ( D&B reference number 06-346-1115)

• $ 300 m turnover with 2500 employees

PARK CORP

Whemco Inc. Manufacturing

Park Corporation

Whemco Inc.

LeHigh Heavy Forge

Corporation

Duraloy Technologies

Inc.

Whemco Ohio Foundry

Inc.

Whemco Steel Castings

Inc.

Erie Forge & Steel

Inc.

Lehigh Heavy Forge Corporation

• 100 years experience

• 250 t forgings

• Re built computerised oil hydraulic 10000 t press

• 4000t press

• Rolls up to 2000 mm dia145t maximum weight

• Supplier of all US Navy Forgings

• Bethlehem PA (1 hour Newark NJ)FORGED ROLLS

Erie Forge and Steel Inc.

• Specialises in ship shafting

• Works in close co operation with LeHigh Heavy Forge inc

• Heat treatment of long shafts

• Machining of shafts up to 22 m

• Erie PA

Whemco Steel Casting Inc.

• 100 t arc furnace

• Rolls cast directly on to metal mould

• Back Up rolls are double poured: A unique “World Class” product

• Selas Differentially Hardening

• Steel Industry castings including slag pots and stainless steel coiler drums.

• Midland Foundry Pittsburgh

Whemco Steel Casting Inc. Cast Back Up Rolls: Solidification

• Fast solidification against metal mould gives finer structures

• Excellent central soundness achieved by diluting core with a low alloy steel

• Combines best of static and duplex technologywith DH hardening

• Up to 6 cast BU and 4 Section produced per weekCAST BU

ROLLS

Whemco Steel Casting Inc. Cast Back Up Rolls: Dilution Process

Bridging and segregation would

occur if solidification was not interrupted.

A hot lower alloy steel dilution of the core is used

to remove segregates

The improved temperature distribution

allows Progressivesolidification to

continue

The final roll has an internal

Soundnessequivalent toForged roll

Whemco Steel Casting Inc. Cast Back Up Rolls: Hardening Process

• ALL BU rolls differentially hardened using a Selas furnace

• Largest hardening unit in US and Europe

• Unique double hardening treatment for 5% Cr BU rolls

• Tough centre allows severe water quench to give up to 125 mm radial hardened depth

Whemco Steel Casting Inc. Cast Back Up Rolls: Size capability

          Recommended

  Grade Max Dia Cast Heat Hardness range Shore C

Type Cr mm Method Treatment Min Max             

Cast 3 1650 Diluted DH 58 70

Cast 5 1650 Diluted DH 60 75

Whemco Ohio Foundry Inc.

• Spin casting technology

• Rolls size up to 1100 mm

• Rolls for hot strip mills

• CNC finishing lathes

• Static Cast Iron BU and Plate mill rolls

• Ohio foundry at Lima Ohio

Whemco Ohio Foundry Inc.

• Investment programme– Melting furnaces–

• Computer modelling usedto ensure product consistency

• Thermal analysis of each melt carried out to ensure consistency.

• Produce full range of alloy white irons: IC; HiCr; and enhanced carbide rolls

Whemco Ohio Foundry Inc.High Chromium Irons: Shell

TC Si S P Mn Ni Cr Mo

ShellHCI Hot

mill 2.40 0.50 0.02 0.04 0.65 0.40 16.50 1.00

2.70 0.75 max max 0.85 0.85 17.50 1.55

Whemco Ohio Foundry Inc.High Chromium Irons: Cores

TC Si S P Mn Ni Cr Mo MgCoreFlake 2.80 1.20 0.05 0.06 0.40 <2.00 <0.20

3.00 1.60 max max 0.60

SG 2.80 1.20 low 0.06 0.20 <2.00 <0.20 <0.08

3.00 2.00 max 0.40

Whemco Ohio Foundry Inc.IDCP: Shells NHI Grades

TC Si S P Mn Ni Cr Mo

ShellNHI-450 3.10 0.85 0.05 0.06 0.40 4.50 1.50 0.30

3.50 1.10 max max 0.50 5.00 1.90 0.50

NHI- Tec 3.10 0.85 0.05 0.06 0.80 4.50 1.50 0.30

3.50 1.10 max max 1.00 5.00 1.90 0.50

Whemco Ohio Foundry Inc.IDCP: Shells NHI Hardness

Typical Hardness RangeEquitip Ld

ShellNHI-450 770 790

NHI-450M 770 800

Whemco Ohio Foundry Inc.Developments

• New 5T and 2T furnaces will allow production of enhanced carbide and HSS rolls.

• Enhanced carbide rolls with weights above 12500 kgm are already been produced.

• Triple pour HSS rolls will be produced in 2006

Duraloy Technologies Inc.

• Horizontal spin casting of heat resisting steels

• Petrochemical reactor tubing

• Tunnel furnace rollers

• Plate hardening furnace rollers

• Scottdale PA ( 1hr South Pittsburgh)

Duraloy Technologies Inc. Tunnel Furnace Rollers (CSP mills)

• Wet Rollers

• Used in heating zones

• 28 Cr 48 Ni plus W

• Refractory coated only tyre in contact

• Operate up to 1260 ºC

Duraloy Technologies Inc. Tunnel Furnace Rollers (CSP mills)

• Dry Rollers (Ni Cr Co W alloys)

• Replace wet rollers in shuttle zone.

• 10% less purchases for warping and refractory replacement

• Dry rollers in use >2years

• Less energy used. Typically €85 k euro/yr

• Reduced water treatment costs

•High temperature cast alloy 20% Cr 30% NiResists deformation / crack propagation / scale pickup

•Thermo-mechanical stress analysisExtends campaign life / reduces repair cost

•Advanced foundry technologyProduces largest size drum casting in the world

Steckel Mill Coiler Drums

BU

Structure

Whemco Inc. Summary Roll capabilities:

Barrel    

Min Dia. Max Dia. Max Length Max TotalMax Finished

mm mm mm length mm Weight Kgm.     

Cast BU Rolls 800 1650 3900 6350 65,000

       

Forged BU Rolls 800 2000 4000 7000 145,000

       

Spun Cast Work Rolls 500 1100 3350 5350 15,000

       

Forged Work Rolls 400 800 2250 4000 12,000

Whemco Inc. Summary Key Strengths:

• Financially strong corporate structure

• 3rd largest Rollmaker in the western world

• Manufacturer of unique range of “World Class” cast BU rolls

• Largest Forgemasters in the western world

• Target is a long term development of export sales and Service