Optimising centrifugal cast compound rolls for metalworking industry

Purpose and goal

The purpose with the project was to evaluate how computational tools can be used as a tool for alloy development. Special interest in this work was centrifugal casted rolls for metalworking industry. By using thermodynamic simulation tools the casting process has been simulated and optimised. The simulation results have been compared to experimental observations, and the method was determined to be reliable and a useful tool for material development at Åkers.

Expected results and effects

Many different material combinations have been tested by computational methods, and only a few of these combinations were believed to be promising material combinations. The casting process was simulated for these material combinations and a final optimised combination was selected. This process has shortened the time for material development, making it possible to early reject those materials that are not promising for further evaluation. The computational method evaluated in this work will be used in future material development at Åkers.

Planned approach and implementation

The first part of the project focused on evaluating and demonstrating casting simulations. The simulation results were compared with characterised production rolls. Material optimisation was then made, and variations in compositions were systematically evaluated for the rolls. The most promising candidate was decided and the experimental work was Åkers was made. Small laboratory castings were produced, characterised and mechanically tested. Early results are promising, although further evaluation will be made after the project.