WA Corresist - The Welding Alloys group

ACTING GLOBALWELDING LOCALWA CorresistInnovative solutions forcladding upper segment rolls

WA CorresistCorresist wire is the latest in a long line of flux-cored wire claddingproducts from Welding Alloys which offers outstanding performancefor use in continuous casting. This particular product is designedfor overcoming the aggressive corrosion & wear associated with therolls located in upper segments of continuous casting machines.Why develop WA Corresist?Molten steelWA Corresist WiresCorresist is the result of continued research & development at Welding Alloys. The new wireis an iron-based super alloy and offers outstanding results through performing exceptionallywell in high temperatures where corrosion and wear take place.Extensive experience with Continuous Casting rolls clad with Corresist wire on foot rolls andupper bender segments of Continuous Casting machines have taken place in Steel plantsacross the world.The upper segment rolls support the partially solidifiedslab/billet (10-22mm skin thickness), with a surfacetemperature of around 1000°C in order to overcomethe bulging of the slab due to ferrostatic pressure ofthe liquid. The upper segment rolls are spaced withsmall roller pitch.These rolls are subjected to extreme temperaturesas a result of direct contact with the slab/billet andradiation. Subsequent air and water cooling of therollers generates the surface stresses and thermalcracking. In addition, the slab skin is covered by amould flux which typically contains inorganic fluorides(i.e CaF2). The reactions between cooling water andmould flux by-products generate a very acidic andcorrosive environment with an acidity of 3-4pH andforming products HCl, CO2, H+ and HF. This corrosiveand abrasive environment resulting in severe surfacedeterioration on the rolls.As a result of this scenario WA Corresist has beendeveloped and performs exceptionally well in thishighly corrosive environment.CorresistClad rollsSchematic diagram illustratingthe application of Corresist in theContinuous Casting Process.Water spraynozzlesCopper mouldCorresistclad toprollersCorresist clad rolls prior tomachining and finishingCorresist’s unparalleled performance results in the longer operating life of the rolls, reducedoffline maintenance and lower operating costs for continuous casting production lines.Corresist wire features:• Iron based super-alloy• Excellent oxidation and corrosion resistance• Microstructurally stable at high temperatures• Service life comparable to Nickel based alloys• Available in the following diameters 1.6, 2.0, 2.4 and 3.2mm• WAF325 and WAF415 flux is recommended• Open arc / submerged arc and gas shielded wire versionsare availableCorresist clad roll benefits:• Reduced maintenance costs• Improved caster utilisation & productivity• Reduction in off-line maintenanceand roll swap outs• Improved slab / billet quality• A reduced number of breakoutsMachined Continuous castingrolls clad with Corresist wireCorresist Submergedarc weldingCorresist proves its worth againA steel factory located on the North Americancontinent had its foot rolls clad with Corresistwire for performance trials in its slab castcontinuous casting line to overcome extremecorrosion conditions.The mould segment had to be changed afterjust 400 heats due to wear on 17-4 type stainlesssteel material at which time the Corresistfoot rools were surveyed and showed no signof significant wear. The rolls clad with Corresisthave been in-service now for more than 1,400heats.Achieved more than 3 times thelife compared to 17-4 SS rolls.Customer Case StudiesAsia/Pacific steelworks benefitsfrom outstanding roll performanceA leading steel manufacturer has been using rollsclad with Corresist in their upper Segments 1-5 fora number of years. Exceptionally long life has beenachieved due to the outstanding performance ofCorresist. The picture (left) shows a typical rollsurface in Segment 4 after 17,395 heats (4.6 milliontonnes of steel). Rolls are found to have little or nowear and are put in service for further use.Life comparable tonickel base alloy.Corresist consistently performs in EuropeExtensive trials at an Eastern-European steelplant have proved that Corresist clad foot rollsand upper segment rolls have performedconsistently well in their slab cast continuouscasting line.The picture (left) shows the foot rolls during aninterim inspection after 550 heats. The top rollis clad with Corresist versus the bottom cladwith martensitic steel. The trials with Corresistclad foot rolls were comparable with thoseobtained with Nickel-based alloys.Wear Comparison of Corresist clad roll (top)versus Martensitic clad roll (bottom)”

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