Aws D14.7-2005

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1st Edition
Prepared by the
American Welding Society (AWS) D14 Committee on Machinery and Equipment
Under the Direction of the

AWS Technical Activities Committee
Approved by the
AWS Board of Directors
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This standard provides guidance, based upon experience, for preparing, building up and overlaying by welding,
postweld heat treating, finish machining, inspecting, and record-keeping of new and reconditioned industrial mill rolls.
550 N.W. LeJeune Road, Miami, FL 33126

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International Standard Book Number: 0-87171-028-5

American Welding Society
550 N.W. LeJeune Road, Miami, FL 33126
© 2005 by American Welding Society
All rights reserved
Printed in the United States of America
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All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American
Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the
American National Standards Institute (ANSI). When AWS standards are either incorporated in, or made part of,
documents that are included in federal or state laws and regulations, or the regulations of other governmental bodies,
their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be
approved by the governmental body having statutory jurisdiction before they can become a part of those laws and
regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes the
AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS
standard must be by agreement between the contracting parties.
AWS American National Standards are developed through a consensus standards development process that brings
together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the process
and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or
verify the accuracy of any information or the soundness of any judgments contained in its standards.
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether
special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance
on this standard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information
published herein.
In issuing and making this standard available, AWS is not undertaking to render professional or other services for or on
behalf of any person or entity. Nor is AWS undertaking to perform any duty owed by any person or entity to someone
else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the
advice of a competent professional in determining the exercise of reasonable care in any given circumstances.
This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.
Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard accept
any and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement of
any patent or product trade name resulting from the use of this standard.
Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.
On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discovered, are posted
on the AWS web page (www.aws.org).
Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request,
in writing, to the Managing Director, Technical Services Division, American Welding Society, 550 N.W. LeJeune Road,
Miami, FL 33126 (see Annex B). With regard to technical inquiries made concerning AWS standards, oral opinions
on AWS standards may be rendered. However, such opinions represent only the personal opinions of the particular
individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official
or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a
substitute for an official interpretation.
This standard is subject to revision at any time by the AWS D14 Committee on Machinery and Equipment. It must be
reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations,
additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should be
addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS D14 Committee on
Machinery and Equipment and the author of the comments will be informed of the Committees response to the
comments. Guests are invited to attend all meetings of the AWS D14 Committee on Machinery and Equipment to
express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are
provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from
the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.
iii
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AWS D14 Committee on Machinery and Equipment
J. L. Warren, Chair CNH America LLC
D. J. Malito, 1st Vice Chair Girard Machine Company, Incorporated
L. L. Schweinegruber, 2nd Vice Chair Robinson Industries, Incorporated
P. Howe, Secretary American Welding Society
D. B. Ashley Hartford Steam Boiler Inspection & Insurance Company
B. K. Banzhaf CNH America LLC
P. W. Cameron Crenlo, Incorporated
P. Collins WeldCon Engineering
*R. T. Hemzacek Consultant
*B. D. Horn Consultant
D. J. Landon Vermeer Manufacturing Company
T. J. Landon Chicago Bridge & Iron Company
M. R. Malito Girard Machine Company, Incorporated
*G. W. Martens Grove Worldwide, Incorporated, Manitowoc Crane Group
*D. C. Martinez Danmar Engineering Company, Incorporated
A. R. Mellini Mellini & Associates, Incorporated
*H. W. Mishler Consultant
R. E. Munson M&M Engineering
J. G. Nelson Northrop Grumman
A. R. Olsen ARO Testing, Incorporated
*P. J. Palzkill Consultant
C. R. Reynolds Deere & Company
W. A. Svekric Welding Consultants, Incorporated
E. G. Yevick Weld-Met International Group, Incorporated
*V. R. Zegers R. E. Technical Services, Incorporated
AWS D14H Subcommittee on Surfacing of Industrial Rolls and Equipment

E. G. Yevick, Chair Weld-Met International Group, Incorporated
J. L. Warren, Vice Chair CNH America LLC
P. Howe, Secretary American Welding Society
J. A. Downey Surface Engineering Associates
*B. D. Horn Consultant
E. Jan ESAB Group, Incorporated
D. J. Kotecki The Lincoln Electric Company
R. Menon Stoody Company
*R. E. Munson M&M Engineering
*L. L. Schweinegruber Robinson Industries, Incorporated
M. D. Tumuluru U.S. Steel Corporation
*Advisor
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This foreword is not a part of AWS D14.7/D14.7M:2005, Recommended Practices for Surfacing
and Reconditioning of Industrial Mill Rolls, but is included for informational purposes only.
With the increasing use of welding to repair and build up industrial rolls, the AWS D14 Committee on Machinery and
Equipment saw a need to provide guidance in this application of welding so that standard procedures and recommen-
dations could be established. With the critical applications in which these rolls are often used, it is important to have
guidelines for properly repairing or reconditioning them.
While welding (mainly submerged arc welding) has been used for repairs and recondition of industrial mill rolls for
a number of years prior to the issuance of this standard, it was felt that an industry standard should be developed to
provide guidance in the proper application of this process. Work on this first edition began in the mid-1990s and has
culminated in the publication of this standard in 2005.
Your comments for improving the Recommended Practices for Surfacing and Reconditioning of Industrial Mill Rolls
are welcome. Submit comments to the Managing Director, Technical Services Division, American Welding Society,
550 N.W. LeJeune Road, Miami, FL 33126; telephone (305) 443-9353; fax (305) 443-5951; e-mail info@aws.org; or
via the AWS web site <http://www.aws.org>.
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Personnel......................................................................................................................................................................v
Foreword ....................................................................................................................................................................vii
Table of Contents.........................................................................................................................................................ix
List of Tables ...............................................................................................................................................................xi
List of Figures.............................................................................................................................................................xii
1. Scope.....................................................................................................................................................................1
2. Normative References .........................................................................................................................................1
2.1 AWS References..........................................................................................................................................1
2.2 ASTM References .......................................................................................................................................1
3. Definitions ............................................................................................................................................................3
4. Base Materials for Rolls, Arbors, Sleeves, and Fabricated Journals .............................................................3
4.1 Overview......................................................................................................................................................3
4.2 Chemical Composition ................................................................................................................................3
4.3 Weldability ..................................................................................................................................................4
4.4 Mechanical Properties .................................................................................................................................4
4.5 Thermal Processing .....................................................................................................................................5
5. Surface Preparation ............................................................................................................................................5
5.1 General.........................................................................................................................................................5
5.2 Stress Relieving Prior to Processing............................................................................................................5
5.3 Surface Condition ........................................................................................................................................5
5.4 Methods of Cleaning....................................................................................................................................5
5.5 Inspection after Cleaning.............................................................................................................................6
5.6 Premachining for Welding...........................................................................................................................6
5.7 Inspection after Machining ..........................................................................................................................6
5.8 Documentation and Reporting.....................................................................................................................6
6. Welding Consumables.........................................................................................................................................6
6.1 Overview......................................................................................................................................................6
6.2 Flux Types ...................................................................................................................................................7
6.3 Wire Electrodes ...........................................................................................................................................7
7. Properties of Weld Deposits ...............................................................................................................................7
7.1 General.........................................................................................................................................................7
7.2 Properties and Composition of Buildup Materials ......................................................................................7
7.3 Properties and Composition of Overlay Materials ......................................................................................9
8. Welding Techniques and Process Control ......................................................................................................11
8.1 Overview....................................................................................................................................................11
8.2 Preheat and Interpass Temperature............................................................................................................11
8.3 Body Run-Off Rings..................................................................................................................................13
8.4 Welding Parameters...................................................................................................................................13
8.5 Considerations Specific to Journal Repair, Buildup, or Overlay...............................................................20
8.6 Postweld Heat Treatment...........................................................................................................................22
ix
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9. Procedure Qualification and Tests ..................................................................................................................23
9.1 Procedure Qualifications (WPS)................................................................................................................23
9.2 Procedure Qualifications (PQR) ................................................................................................................23
9.3 Type of Tests Required..............................................................................................................................23
10. Repair and Correction ......................................................................................................................................33
10.1 General.......................................................................................................................................................33
10.2 Examples of Nonconformance ..................................................................................................................33
10.3 Purchasers and Manufacturers Obligations.............................................................................................33
11. Finish Machining and Final Inspection...........................................................................................................33
11.1 Setup ..........................................................................................................................................................33
11.2 Rough Machining ......................................................................................................................................33
11.3 In-Process Inspection.................................................................................................................................33
11.4 Final Machining.........................................................................................................................................34
11.5 Final Inspection .........................................................................................................................................34
11.6 Nonconformance........................................................................................................................................34
11.7 Documentation and Reporting...................................................................................................................34
12. Quality Assurance .............................................................................................................................................34
12.1 General.......................................................................................................................................................34
12.2 Quality System Outline .............................................................................................................................34
Annex A (Informative)Flux and Wire Consumables .............................................................................................37
Annex B (Informative)Guidelines for Preparation of Technical Inquiries for AWS Technical Committees........41
Annex C (Informative)Recommended Forms ........................................................................................................43
Annex D (Informative)Bibliography......................................................................................................................51
List of AWS Documents on Machinery and Equipment............................................................................................53
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1 Typical Chemical Composition and Mechanical Properties of Typical Forged Roll Materials ....................4
2 Carbon Equivalent and Associated Preheat Temperatures of Typical Forged Materials ..............................5
3 Typical All-Weld-Metal Compositions Used for Industrial Mill Rolls .........................................................8
4 Typical Properties of Low Alloy Buildup Materials Deposited Using Neutral SAW Fluxes .......................9
5 Hardness (HRC) as a Function of Heat Treatment for 12% Cr Stainless and Tool Steel Overlays
(4 Hours at Temperature) ...............................................................................................................................9
6 Tensile Properties as a Function of Temperature for Some Stainless Overlays ..........................................10
7 Impact Toughness of Some Stainless Steel Overlays ..................................................................................10
8 Typical Parameters for Tubular Submerged Arc Wires...............................................................................14
9 Wire Feed Speed to Travel Speed Ratios Which Produce a Weld Buildup Cross-Sectional
Area of about 0.06 in.2 [40 mm2].................................................................................................................14
10 Suggested Electrode Displacement from Roll Top Dead Center.................................................................18
11 Calculated Cr Content of Various Layers of Overlay vs. Dilution for a Flux-Wire
Combination Producing 13% Cr All-Weld-Metal .......................................................................................19
12 Sample Types vs. Qualification Levels........................................................................................................24
13 Welding Process Variables ..........................................................................................................................24
xi
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1 Typical Roll Types and Nomenclature ..........................................................................................................2
2 View of Typical Roll Cross Section ..............................................................................................................3
3 Preheat Temperature as a Function of Carbon and Alloy Content ..............................................................12
4 Required Soak Time at Temperature to Heat the Roll Through Its Diameter as a Function of Diameter...12
5 Preheat Temperature Effect on Roll Diameter Expansion...........................................................................13
6 Overlay Beads Deposited at Wire Feed Speed (wfs) to Travel Speed Ratio of 5 to 1,
1/8 in. [3.2 mm] Wire Diameter, 28 Volts DCEP........................................................................................15
7 Overlay Beads Deposited at 180 ipm [76 mm/sec] Wire Feed Speed, 1/8 in. [3.2 mm]
Wire Diameter, Varying Voltage .................................................................................................................16
8 Overlay Beads Deposited at Wire Feed Speed (wfs) to Travel Speed Ratio of 5 to 1,
1/8 in. [3.2 mm] Wire Diameter, 28 Volts DCEN .......................................................................................16
9 Effect of Stepover at 100 ipm [42 mm/sec] Wire Feed Speed (480 A) with 1/8 in. [3.2 mm]
Wire, DCEP .................................................................................................................................................17
10 Effect of Electrode Position on Bead Shape, Slag Spillage, and Flux Spillage...........................................18
11 Effect of Lead Position on Bead Solidification Lines..................................................................................19
12 Stepover Techniques ....................................................................................................................................22
13 Basic Bead on Plate Sample for Level 1 Qualification................................................................................27
14 Roll Cylinder Sample for Level 1, 2, or 3 Qualification..............................................................................27
15 Roll Qualification TestsQualification of HardfacingLocation of Rockwell Hardness
Test Samples 1A1, 2B1, 2C1 .......................................................................................................................27
16 Roll Qualification TestsQualification of HardfacingSample Layout and General Description ..........28
17 Roll Buildup Qualification TestsSample Roll Configuration Prior to Welding ......................................29
18 Roll Buildup Qualification TestsQualification of BuildupLocation of Test Samples .........................30
19 Level 1 Tensile Test for Journal and Buildup Materials..............................................................................31
20 Roll Qualification TestsQualification of HardfacingLocation of Chemical Analysis
SamplesSample 1A1 ................................................................................................................................32
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C.1 Sample Form for Incoming and Final Inspection Records ..........................................................................44
C.2 Sample Form for Welding Procedure Specification ....................................................................................45
C.3 Sample Form for Procedure Qualification Record ......................................................................................46
C.4 Sample Form for Welder and Welding Operator Qualification Test Record ..............................................47
C.5 Sample Form for Recording Weld Processing Parameters ..........................................................................48
xii
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1. Scope Welding symbols shown on drawings should be compat-

ible with those shown in AWS A2.4, Standard Symbols
An industrial mill roll can be defined as any roll or cylin- for Welding, Brazing, and Nondestructive Examination.
drical body that transports, processes, guides or performs Special conditions or deviations should be fully ex-
a function in creating a product in the heavy metals, plained by added notes, details, or definitions.
paper, plastic, or lumber industries. These rolls can come
in many shapes and sizes (as shown in Figure 1), and
include, but are not limited to, table rolls, guide rolls,
caster rolls, pinch rolls, leveler rolls, straightener rolls,
bridle rolls, and blocker rolls.
2. Normative References
The following standards contain provisions which,
This standard provides guidance, based upon experience,
through reference in this text, constitute provisions of
for preparing, building up and overlaying by welding,
this AWS standard. For undated references, the latest
postweld heat treating (PWHT), finish machining,
edition of the referenced standard shall apply. For dated
inspecting, and record-keeping of new and reconditioned
references, subsequent amendments to, or revisions of,
industrial mill rolls. While mainly used in the primary
any of these publications do not apply.
metal-working industry, industrial mill rolls are also
used in other applications. Because common practice 2.1 AWS References1
predominately employs submerged arc welding (SAW),
this document emphasizes SAW. However many of the 1. AWS A2.4, Standard Symbols for Welding, Brazing,
principles are applicable, with suitable modifications, to and Nondestructive Examination
gas metal arc welding (GMAW), flux cored arc welding
(FCAW), and electroslag cladding. 2. AWS A3.0, Standard Welding Terms and Definitions
This standard makes use of both U.S. Customary Units 3. AWS A5.17, Specification for Carbon Steel Elec-
and the International System of Units (SI). The measure- trodes and Fluxes for Submerged Arc Welding
ments may not be exact equivalents; therefore each sys-
4. AWS A5.23, Specification for Low Alloy Steel
tem should be used independently of the other without
Electrodes and Fluxes for Submerged Arc Welding
combining in any way. The designation D14.7 uses U.S.
Customary Units. The designation D14.7M uses SI 5. AWS B4.0, Standard Methods for Mechanical
Units. The latter are shown in appropriate columns in Testing of Welds
tables and figures or within brackets [ ]. Detailed dimen-
sions on figures are in inches. A separate tabular form 2.2 ASTM References2
that relates the U.S. Customary Units with SI Units may
be used in tables and figures. 1. ASTM A 388, Standard Practice for Ultrasonic
Examination of Heavy Steel Forgings
Safety and health issues and concerns are beyond the
scope of this standard, and therefore are not fully 1 AWS standards are published by the American Welding
addressed herein. Safety and health information is avail- Society, 550 N.W. LeJeune Road, Miami, FL 33126.
able from other sources, including, but not limited to, 2 ASTM standards are published by the American Society for
ANSI Z49.1, Safety in Welding, Cutting, and Allied Pro- Testing and Materials, 100 Barr Harbor Drive, West Consho-
cesses, and applicable federal and state regulations. hocken, PA 19428-2959.
1
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Figure 1Typical Roll Types and Nomenclature
2
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2. ASTM E 165, Standard Test Method for Liquid expressed as the percentage of base metal or previous
Penetrant Examination weld metal in the weld bead.
3. ASTM E 709, Practice for Magnetic Particle journal. The part of the roll which provides support for
Examination the roll and can contain components like bearings,
seals, and chocks (see Figure 1).
4. ASTM G 48, Standard Test Methods for Pitting and
Crevice Corrosion Control Resistance of Stainless Steels overlay, industrial rolls. The process of creating the
and Related Alloys by Use of Ferric Chloride Solution final composition and mechanical properties of the
surface of the roll. The welding overlay is intended to
enhance or restore the service performance of the roll
(see Figure 2).
3. Definitions roll body. The part of the roll area which is in contact
with the product being supported, transported, or
Welding terms used in this standard are in accordance shaped (see Figure 1).
with AWS A3.0, Standard Welding Terms and Defini-
spalling. The breaking of weld metal particles away
tions, which should be referred to for a complete list of
from the base metal or previous hardfacing layers.
terms used in welding. The terms that follow are defined
specifically for the purpose of this recommended prac-
tice and may be a variation of the term as defined in
AWS A3.0. 4. Base Materials for Rolls, Arbors,
Sleeves, and Fabricated Journals
buildup, industrial rolls. A process of either filling in a
void or enlarging an undersized component roll. This 4.1 Overview. The selection of materials for rolls is gen-
process can be performed on a roll body or journal. erally based on the conditions the roll will see in service
The weld buildup used in this process typically and whether the roll is to be reconditioned or overlaid at
matches or exceeds the mechanical properties of the some point in its life. The material procurement specifi-
base metal. cation for a new roll should include material grade,
method of manufacture (casting, forging, rolling, etc.),
buttering. The process of creating an intermediate weld heat treatment and hardness. For a reconditioned roll,
layer that allows an overlay or buildup material to be efforts should be made to establish the composition and
used without creating a crack sensitive alloy. A butter hardness for both the base metal and the surfaces to be
layer provides good weldability between a base metal reconditioned. Mechanical properties, thermal process-
and an overlay. The butter layer(s) used in this pro- ing, and weldability of the material are important consid-
cess typically dilutes and mixes with the base material erations generally incorporated into the specification for
to create a weldable alloy. the roll.
dilution. The change in chemical composition of the 4.2 Chemical Composition. Different base materials
weld metal caused by the admixture of the base metal require different welding techniques and precautions to
or previous weld metal in the weld bead. It is prevent cracking. Requirements for preheat, postweld
Figure 2View of Typical Roll Cross Section
3
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heat treatment, and interpass temperature all vary with Table 2 shows the CEIIW of commonly used forged roll
carbon equivalent (CEIIW). Therefore, it is essential that materials and the suggested minimum preheat tempera-
the compositions of base materials be known before tures. Generally, the higher the carbon equivalent, the
welding. Chemical analysis is recommended to provide higher the required preheat temperature.
information regarding the general weldability of the base
4.4 Mechanical Properties. The two most important
metal, the presence of elements detrimental to welding mechanical properties for the roll prior to overlaying are
(i.e., high P, high S, or high V), and the sensitivity to yield strength and toughness. The yield strength, at room
stress relief cracking. Table 1 shows the chemical com- temperature or at the elevated temperatures the roll might
position of commonly used forged roll materials. see in service, should be high enough to support the load
and resist permanent bending. The toughness of the roll,
4.3 Weldability. AWS A3.0 defines weldability as the
as measured by the Charpy V-notch impact test, is an
capacity of the material to be welded under the imposed
indication of the resistance to catastrophic failure from
fabrication conditions into a specific, suitably designed
small defects or surface cracks that might initiate and
structure and to perform satisfactorily in the intended
propagate during service. The tests used to measure these
service. Weldability is also the ability to weld a material
properties are generally performed in accordance with
without introducing any cracks or other defects and to appropriate ASTM standard procedures.
achieve the desired properties for the intended applica-
tion. Over the years, attempts have been made to provide Occasionally rolls are procured to hardness requirements
single numbers to characterize the weldability of steels to only. The approximate yield strength and tensile strength
cover heat-affected zone (HAZ) hardenability and HAZ properties of the roll can be estimated from the Brinell
hydrogen cracking tendency. The most useful formula hardness, using the following general rules of thumb:
for hardenability was simplified by a subcommittee of 1. Tensile Strength (ksi) is approximately (Brinell
the International Institute of Welding (IIW) into the fol- Hardness10)/2
lowing carbon equivalent formula (Equation 1):
2. Yield Strength (ksi) of a quenched and tempered
Equation 1: low alloy steel roll is typically 75% to 80% of the tensile
strength.
CEIIW = %C + %Mn/6 + %(Cr + Mo +V)/5
+ %(Ni + Cu)/15 Table 1 shows the mechanical properties of commonly
used forged roll materials. Other materials not listed in
Note: Generally, steels with CEIIW values above 0.5 the table may be used. Technical information for these
are more difficult to weld. materials can usually be obtained from the roll supplier.
Ì¿¾´» ï
Ì§°·½¿´ Ý¸»³·½¿´ Ý±³°±-·¬·±² ¿²¼ Ó»½¸¿²·½¿´ Ð®±°»®¬·»- ±º Ì§°·½¿´ Ú±®¹»¼ Î±´´ Ó¿¬»®·¿´- ¿
CVN Notch
Yield Strength Toughnessb
Grade C Mn Si Ni Cr Mo V ksi MPa ft-lb J

4130 0.30 0.50 0.22 0.20 0.90 0.20 0.05 75 515 60 81
4140 0.40 0.85 0.22 0.20 0.90 0.20 0.05 90 620 65 88
4340 0.40 0.80 0.30 1.80 0.80 0.25 0.05 130 895 20 27
8620 0.20 0.80 0.22 0.50 0.50 0.17 45 310 90 136
SCM822M 0.23 0.80 0.24 0.65 1.10 0.40 0.07 83 570 160 217
13CrMo44 0.13 0.55 0.22 0.95 0.55 50 345 50 68
16CrMo44 0.17 0.65 0.22 0.20 1.00 0.42 0.05 70 485 200 271
FXLC130 0.19 1.00 0.30 1.30 1.15 0.39 115 795 20 27
Astralloy V 0.23 0.90 0.30 3.50 1.40 0.30 150 1035 20 27
21CrMoV511 0.22 0.40 0.35 0.40 1.30 1.03 0.28 100 690 100 136
a Select data extracted from: Handerhan, K., The Importance of Fracture Mechanics in the Design of Forged Continuous Caster Rolls, Table IV,
Proceedings from the 1989 Mechanical Working and Steel Processing Conference.
b Test Temperature: 70°F [21°C]
Source: Data provided courtesy of the Elwood City Forge Company.
4
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end user and Manufacturer. Consideration should be

Ì¿¾´» î
given to areas adjacent to the weld, since the welding and
Ý¿®¾±² Û¯«·ª¿´»²¬ ¿²¼ ß--±½·¿¬»¼ Ð®»¸»¿¬ heating operations may alter these surfaces to an out-of-
Ì»³°»®¿¬«®»- ±º Ì§°·½¿´ Ú±®¹»¼ Ó¿¬»®·¿´- tolerance condition. Similarly, other areas of the roll,
Minimum Preheat
such as long, small diameter journals, may distort during
Grade CEIIW Temperature, °F [°C] welding which should be considered when developing a
scope of the work.
4130 0.63 350 [180]
4140 0.79 450 [230] 5.2 Stress Relieving Prior to Processing
4340 0.87 500 [260]
8620 0.50 300 [150] 5.2.1 Overview. It is common practice in many shops
SCM822M 0.72 400 [205] to perform a stress relief heat treatment on used rolls
13CrMo44 0.52 250 [120] before beginning the repair process. The stress relief
16CrMo44 0.59 325 [165]
FXLC130 0.75 425 [220]
treatment should be conducted at a temperature that does
Astralloy 0.95 550 [290] not alter the mechanical properties of the rolls base
21CrMoV511 0.83 425 [220] material. This thermal treatment serves to reduce stresses
from both processing and service conditions. It can also
Source: Data provided courtesy of The Stoody Company and derived
from the graphs in Figure 3. reduce the hardness of the roll surface to facilitate easier
machining and undercutting for repair.
5.2.2 Parameters. The stress relief temperature is

based upon the chemical composition of the base mate-
rial but is typically between 900°F [480°C] and 1150°F
4.5 Thermal Processing. The heat treatment given a roll
[620°C]. Heating and cooling rates are a function of the
is important in that it not only establishes the required
mass, configuration, and composition of the rolls base
mechanical properties, but also, to some extent, controls
material. These can range from a slow rate of 15°F [8°C]
the performance of the roll during service. Ideally, the
per hour to a fast rate of 200°F [110°C] per hour. There
selection of the base material and its thermal processing
is significant risk that heating too quickly or causing
should be such that the roll is resistant to degradation of
temperature nonuniformity can cause the rolls base
its mechanical properties during operation at elevated
material to catastrophically fail. The soak time at maxi-
temperatures.
mum temperature is usually based on 0.5 hour per inch
[25 mm] of roll material thickness. These types of treat-
ments are usually performed in a furnace that has tem-
5. Surface Preparation perature uniformity within a range of 50°F [30°C] during
the heating, soak and cooling steps of the treatment. The
5.1 General
capability of the furnace should be known before pro-
5.1.1 Proper preparation of the surface of a roll for cessing rolls.
weld overlay is critical to the success of the welding of
new rolls and reconditioning of used rolls. The roll 5.2.3 Precautions. It might be necessary to protect
should be cleaned, inspected, and cleared of all linear areas of the roll such as journals, keyways, etc., from
indications (cracks) and other defects that could cause scaling during thermal treatment. A suitable high-
potential failures. A qualified inspector (qualified to temperature protective coating may be used to protect
SNT TC-1A, QC1, or other equivalent programs) should areas not intended for subsequent repair.
conduct the inspection of the prepared surface. The sur- 5.3 Surface Condition. The roll should be free of
faces of the roll should be premachined to provide allow- grease, oil, paint, scale, rust and other contaminants prior
ance for the specified deposit thickness and proper to inspection and welding. The condition of the roll sur-
welding techniques. Many cleaning processes can face should be compatible with the inspection method
expose employees and the environment to potentially used.

harmful fumes and particulates. Surface preparation
practices should be reviewed for compliance to applica- 5.4 Methods of Cleaning
ble safety and environmental regulatory standards, and
material safety data sheets (MSDSs) should be consulted. 5.4.1 Degreasing. The surface of the roll may be
cleaned of grease and other hydrocarbon products by
5.1.2 To determine the areas of the roll that require using a suitable degreasing solvent. Additional cleaning
welding, the existing condition of the roll should be com- as required should be performed to provide a clean
pared to the drawing/specifications as agreed upon by the surface.
5
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5.4.2 Baking. The roll can be cleaned in a furnace by 4. Hardness testing (may be conducted to verify the
heating to a temperature sufficient to burn off greases nature of the surface prior to overlaying).
and paints. Temperatures during cleaning should remain
The acceptance criteria for the tests should be established
below the typical base metal tempering range or the
between the end user and the Manufacturer.
properties of the roll could be altered.
5.6 Premachining for Welding
5.4.3 Machining. Machining is an efficient method of
removing rust, scale, and dirt from the roll surface in 5.6.1 General. All of the areas for welding should be
preparation for inspection and welding. Additional machined undersize to allow for the specified weld
degreasing and cleaning may be necessary to remove oil deposit thickness. Additional metal removal may be
or coolant residue from the surface and to clean the areas required if buttered and/or buildup layers are needed
of the roll which were not premachined. between the base metal and final weld deposit. When
premachining the body of the rolls, the deposit thickness
5.4.4 Grinding, Blasting, or Brushing. Hand grind- per pass should be considered so that final machining
ing, sand blasting or wire brushing can be used to occurs within the last overlay layer and not the interface
remove burnt or loose residue from the roll surface. between two layers. Generally, areas requiring welding
When wire brushing, an appropriate type of wire brush should be undercut by machining to a minimum of
suitable with the roll material should be used. Hand 0.040 in. [1 mm] per side.
grinding can be beneficial for localized cleaning.
5.6.2 Radius and Transition Areas. To prevent
5.5 Inspection after Cleaning. Inspection of the roll is stress risers and slag inclusions, welding in sharp corners
recommended after cleaning to develop a scope of the and square shoulders should be avoided. When prema-
work for repairs and to ensure that the roll is properly chining, transitions between different diameters should
prepared for welding. Inspections should be performed be sloped at a 15° angle or greater and the corner radius
and documented as called for by quality requirements, should be at least 1/4 in. [6 mm] or greater.
internal or external. A qualified inspector (qualified to
SNT TC-1A, QC1, or other equivalent programs) should 5.6.3 Defect Removal
conduct the inspection of the prepared surface. A typical 5.6.3.1 Hand Grinding. Short, shallow defects
form for recording incoming inspection results is shown that are small in number can be removed by hand grinding.
in Figure C.1 of Annex C.
5.6.3.2 Machining. To remove numerous or deep
5.5.1 Visual Inspection. The roll should be inspected discontinuities, the area should be machined using a cir-
for its general condition and obvious damage such as cumferential method by plunge or side cutting as neces-
open cracks, spalls, and gouges. The heat identification sary with a lathe tool. After the discontinuity is removed,
number, which can be used to track the data on roll life the sides of the groove should be beveled and the root
and repair history of the roll, should be recorded. The should be radiused to permit complete fusion during the
identification numbers should be permanent markings welding operation.
and should be enhanced, if necessary.
5.7 Inspection after Machining. Nondestructive exami-
5.5.2 Dimensional Inspection. The roll should be nation should be performed using one or more of the
identified and inspected to determine out-of-tolerance methods listed in 5.5.3 to insure the complete removal of
conditions which would affect the performance of the all unacceptable indications.
roll in service. Dimensional inspection should include
the body, bearing journals, seal journals, and drive jour- 5.8 Documentation and Reporting. The documentation
nals. Indicated runout of journals should be measured and reporting of all inspections should be completed
and the results considered when establishing the Scope as called for by quality requirements, internal and exter-
of Work. nal. Refer to Figure C.1, Annex C for typical inspection
documentation.
5.5.3 Nondestructive Examination. 100% nondestruc-
tive examination of all roll surfaces is recommended.

The roll should be inspected by one or more of the 6. Welding Consumables
following nondestructive examination methods:
6.1 Overview. The vast majority of surfacing and recon-
1. Liquid penetrant testing (PT) (see ASTM E 165), ditioning of industrial mill rolls is done by the sub-
2. Magnetic particle testing (MT) (see ASTM E 709), merged arc welding (SAW) process. SAW with strip
electrodes is also used. A limited amount of work is done
3. Ultrasonic examination (UT) (see ASTM A 388), by flux cored arc welding (FCAW) and very minor
6
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amounts are done by shielded metal arc (SMAW), gas rolled, which can result in tangling when the wire is sub-
tungsten arc (GTAW), or gas metal arc welding sequently fed out of the drum into the welding station.
(GMAW). Limited thermal spray has also been applied. Drums should be maintained vertical at all times, to
avoid tangling of the wire.
This section briefly describes SAW consumables. Con-
sumables for SAW include both flux and filler metal.
(Additional details are found in Annex A.)
7. Properties of Weld Deposits
6.2 Flux Types. Fluxes may be produced by:
7.1 General. The choice of filler metals for journal
1. Melting the various oxides and fluorides together, repair, weld buildup, and overlay is primarily dictated by
then crushing to size (fused fluxes); the composition of the roll material and the roll operating
2. Mixing powdered oxides, fluorides, and possibly conditions. For rolling applications that are conducted at
metallic ingredients with a water glass binder, pelletiz- room or ambient temperature, the hardness and the com-
ing, and drying the particles that result (bonded fluxes); pressive strength of the overlay may be the only consid-
eration. For hot rolling applications, the elevated
3. Mechanically mixing the ingredients without a temperature hardness and strength as well as the ductility
bonding agent. are important considerations. This situation could further
From the point of view of metallurgical reactions during be complicated if corrosive conditions accompany the
welding, a given flux may be described as acid, basic, or rolling operation. Typically, buildup and overlay weld-
neutral depending on the various oxides and fluorides ing materials fall into the following four categories for
present in the flux (see A4 for details). Finally, a given industrial roll welding:
flux may contain alloying elements to be added to the 1. Mild steel for journal repair and roll body buttering,
weld metal, or it may be unalloyed. Each flux character-
istic has an influence on the welding results with a given 2. Low alloy steel for journal repair and roll body
welding electrode. Since the SAW fluxes commonly buildup,
used for industrial mill rolls are not classified, it is usu-
ally beneficial to establish a relationship with the flux 3. Stainless steel (12% Cr) overlay, and
supplier to understand the flux characteristics and to 4. Tool steel overlay.
obtain recommendations for flux storage and handling.
As noted above, the mild steel deposition is typically
6.3 Wire Electrodes. Except for a few mild steel elec- aimed to produce an undiluted low-carbon deposit of no
trodes classified according to AWS A5.17, Specification more than 1.6% Mn and 0.8% Si. However, dilution
for Carbon Steel Electrodes and Fluxes for Submerged from the roll body material will generally produce a
Arc Welding, wire electrodes for industrial mill rolls are somewhat higher carbon low-alloy steel deposit. Such
generally not classified by AWS. Solid mild steel elec- deposits are often adequate for journals. The other three
trodes are used for buttered layers and some buildup general alloy categories are aimed at roll body per-
(often in the journal area of a roll). But most buildup and formance and requirements based on the in-service
overlaying are done with tubular wire electrodes. conditions of the roll. The optimum deposit composition
These tubular electrodes may be designed to deposit low- and heat treatment will change from application to
alloy steel (usually for buildup), tool steel (usually for application.
cladding work rolls, guide rolls, and the like where cor- 7.2 Properties and Composition of Buildup Materials
rosion resistance is not an issue), or stainless steel (where
corrosion resistance is important, such as continuous 7.2.1 Properties. Except for chemical composition,
caster rolls which operate in an environment including all properties of buildup materials should be tested in the
spray water as well as mold compounds). A given wire is heat treated condition. The heat treatment of the test pad
generally designed for use with a particular flux to obtain prepared for such tests should correspond to the heat
optimum deposit composition and properties. Therefore, treatment the roll will experience during surfacing and
it is important to follow the wire manufacturers recom- reconditioning.
mendations for flux selection.
7.2.2 Composition. Buildup materials are used to
Wire electrodes for industrial mill roll welding are often bring the journal and roll dimensions up to where suffi-
supplied in drums containing as much as 750 lbs cient overlay material can be deposited so that the
[340 kg] or more. The wire in the drums is laid loosely machined surface of the overlay is at the required chemi-
around a center, not tightly wound as might be on a reel cal composition and therefore has the required properties
or coil. The wire loops can shift if the drum is tilted or for the application. The composition of the buildup
7
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alloys can range from very basic carbon steel to complex tively hard weld deposit may not be desirable because it
low-alloy steel and have been described in the earlier could be more prone to cracking. The hardness of the
section. Some of the typical compositions used for indus- buildup materials will change as a function of the service
trial mill rolls are shown in Table 3. Generally, the sim- temperature of the rolls. A room temperature hardness
ple carbon steels are used to build up dimensions on range may be included in the purchasing specification for
rolls, which do not require high compressive strengths in the buildup materials. A method of deposition (number
their applications. of layers and welding parameters) as well as the accep-
tance/rejection range should be agreed upon between the
Another situation where these low carbon steel composi- Purchaser and the Manufacturer.
tions might be used is where the roll base material is of a
high-carbon, high-hardenability material. The deposition 7.2.4 Tensile Properties. The buildup materials are
of a low-carbon steel will minimize formation of brittle generally chosen so that their tensile strength matches
zones in the first layer of the butter material and there- the tensile properties of the base material. The tensile
fore reduce the risk of cracking. Low-alloy steel deposits properties are typically evaluated with the weld metal in
serve to provide high compressive strength and a tough the heat-treated condition. Tensile properties can be
matrix, which slows crack propagation. requested as a part of the specification. The details of
testing should be worked out between the Purchaser and
For solid (hard) wire filler metals, composition usually the Manufacturer. The methods of weld deposition and
refers to that of the solid (hard) wire itself as specified by testing are well covered by AWS filler metal specifica-
AWS. With tubular wire, the composition refers to that tions AWS A5.17, Specification for Carbon Steel Elec-
of the weld deposit. The composition should be deter- trodes and Fluxes for Submerged Arc Welding, AWS
mined from a pad that is deposited using the welding A5.23, Specification for Low Alloy Steel Electrodes and
parameters and flux and wire combination that represent Fluxes for Submerged Arc Welding, and test specifica-
the actual welding condition. Typically, four or more tion AWS B4.0, Standard Methods for Mechanical Test-
layers of weld metal are deposited to make the pad. The ing of Welds. Typical tensile properties of the low-alloy
chemical analysis is conducted on the last layer. A typi- buildup overlays listed in Table 3 are shown in Table 4.
cal method can be found in AWS A5.23, Specification
for Low Alloy Steel Electrodes and Fluxes for Sub- 7.2.5 Impact Toughness. The impact toughness of
merged Arc Welding, for preparing a weld pad for chem- the buildup material has a significant effect on the ability
ical analysis. of a crack that has developed in the overlay material to
propagate into the roll. The impact toughness is gov-
7.2.3 Hardness. The hardness of the weld deposit erned by several factors:
reflects its tensile strength. It is primarily governed by
1. Composition of the weld deposit,
the carbon content, although the manganese, silicon, and
alloy (e.g., Cr, Mo) levels can also influence it. A rela- 2. Preheat and interpass temperature,
Ì¿¾´» í
Ì§°·½¿´ ß´´óÉ»´¼óÓ»¬¿´ Ý±³°±-·¬·±²- Ë-»¼ º±® ×²¼«-¬®·¿´ Ó·´´ Î±´´-
Low Alloy Build-Up 12% Cr Stainless Steel Overlay Tool Steel Overlay
BU1 BU2 BU3 SS1 SS2 SS3 SS4 TS1 TS2

C 0.15 0.15 0.05 0.16 0.04 0.15 0.12 0.28 0.16
Mn 0.9 0.8 0.6 1.2 1.0 1.2 1.1 1.5 1.2
Si 0.5 0.4 0.4 0.5 0.6 0.5 0.4 0.4 0.6
Cr 1.7 0.5 1.4 12.00 13.00 12.00 13.00 6.5 6.0
Ni 0.5 2.4 4.5 2.0 2.5
Mo 0.6 0.2 0.4 1.0 1.0 1.0 1.0 1.4
V 0.15 0.18 0.15
W 1.0 1.1
Nb 0.18
As-Welded
30 23 25 46 36 44 47 52 45
Hardness (HRC)
Source: Data provided courtesy of The Stoody Company.
8
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The composition of the overlay determines its as-welded

Ì¿¾´» ì hardness, room and elevated temperature strength, and
Ì§°·½¿´ Ð®±°»®¬·»- ±º corrosion resistance. Other significant properties are
Ô±© ß´´±§ Þ«·´¼«° Ó¿¬»®·¿´- resistance to fire-cracking (thermal fatigue) and resis-
Ü»°±-·¬»¼ Ë-·²¹ Ò»«¬®¿´ ÍßÉ Ú´«¨»- tance to wear which are primarily governed by the hot
hardness (hardness at service temperatures).
BU1a BU2a BU3b
7.3.2 Hardness. The as-welded hardness of an over-
Tensile Strength, ksi [MPa] 125 [860] 99 [680] 99 [680] lay is determined primarily by its carbon content. The
Yield Strength, ksi [MPa] 112 [770] 85 [585] 87 [600]
Elongation, % 19 24 23 higher the carbon content, the higher is the hardness of
Reduction in Area, % 58 65 the overlay. The resistance to tempering is an important
Impact Toughness, ft-lbs [J] 75 [102] 102 [138] characteristic since welded rolls are usually postweld
@ 70°F [21°C] heat treated (PWHT) to relieve residual stresses and
a PWHT 6 hrs @ 1175°F [635°C] restore some ductility from the as-welded condition. Car-
b PWHT 2 hrs @ 1200°F [650°C] bide formers, such as V, Nb, and W, are added to the
Source: Data provided courtesy of The Stoody Company. composition to improve the resistance to tempering.
Table 5 shows the change in hardness (at room tempera-
ture) as a function of tempering temperature for the stain-
less and tool steel overlays described in Table 3. It is
clear that the unstabilized overlays such as SS1 and SS2
soften rapidly with temperatures approaching 1100ºF
3. Welding heat input, [595ºC]. The finished hardness of the overlay should be
agreed upon between the roll manufacturer and the user.
4. PWHT temperature and time, and
7.3.3 Elevated Temperature Strength and Ductil-
5. Types of welding flux and wire. ity. For rolls that are used at relatively high temperatures
(such as continuous caster rolls), the elevated tempera-
Acidic fluxes will result in deposits of relatively low ture strength and ductility may be properties of concern.
impact toughness when compared to the basic fluxes. The yield strength and ductility at elevated temperature
Even among the basic fluxes, the makeup of the fluxes will govern the ability of the overlay to withstand plastic
can result in significantly different oxygen and inclusion deformation. Table 6 shows elevated temperature prop-
contents in the overlay, thus affecting the toughness. erties for two commonly used stainless steel overlays. As
Typical impact toughness of the buildup materials is expected, higher strengths imply lower ductility. The
shown in the Table 4. need for elevated temperature properties should be speci-
fied separately between the supplier and the user.
Additionally, toughness may be influenced by repeated
heating and cooling thermal cycles as well as exposure 7.3.4 Impact Toughness. The impact toughness of
to elevated temperatures. Many of the buildup materials overlays has significance in that this property will dictate
that are essentially chromium-molybdenum steels can
embrittle in service depending on their composition
(particularly those with higher levels of residual elements
P, Sn, Sb, or As) and the thermal history to which they
have been subjected.
Ì¿¾´» ë
7.3 Properties and Composition of Overlay Materials
Ø¿®¼²»-- øØÎÝ÷ ¿- ¿ Ú«²½¬·±² ±º Ø»¿¬
7.3.1 Composition. The composition of overlay materi- Ì®»¿¬³»²¬ º±® ïîû Ý® Í¬¿·²´»-- ¿²¼ Ì±±´
als can range from simple low-alloy steels to stainless Í¬»»´ Ñª»®´¿§- øì Ø±«®- ¿¬ Ì»³°»®¿¬«®»÷
steels and tool steel materials. Typical compositions are
ºF [ºC] SS1 SS2 SS3 SS4 TS1 TS2
shown in Table 3. As in the case of the buildup materials,
the compositions are defined by the wire/flux combination, 900 [480] 44 36 46 45 52 46
welded in a predefined manner. Generally, the composition 1000 [540] 32 30 38 41 50 35
1100 [595] 27 24 33 34 40 a32 a
of the undiluted weld metal is specified. The method of a30 a
1200 [650] 23 23 32 33 36
deposition used to produce the weld pad for chemical anal-
ysis and the associated welding parameters should be a Estimated
agreed upon between the consumable supplier and the user. Source: Data provided courtesy of The Stoody Company.
9
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Ò± ®»°®±¼«½¬·±² ±® ²»¬©±®µ·²¹ °»®³·¬¬»¼ ©·¬¸±«¬ ´·½»²-» º®±³ ×ØÍ Ò±¬ º±® Î»-¿´»
Ì¿¾´» ê
Ì»²-·´» Ð®±°»®¬·»- ¿- ¿ Ú«²½¬·±² ±º Ì»³°»®¿¬«®» º±® Í±³» Í¬¿·²´»-- Ñª»®´¿§- ¿
Tensile Strength Yield Strength
Test ksi [MPa] ksi [MPa] Elongation (%) Reduction in Area (%)
Temperature
°F [°C] SS1 SS4 SS1 SS4 SS1 SS4 SS1 SS4
70 [21] 143.6 [990] 167.0 [1151] 118.4 [816] 132.6 [914] 19 12 60 35
800 [425] 109.8 [757] 130.7 [901] 93.3 [643] 112.7 [777] 15 7 64 22
1000 [540] 83.1 [573] 106.2 [732] 72.2 [498] 72.2 [498] 25 13 76 55
1200 [650] 50.4 [347] 69.9 [482] 34.6 [239] 34.6 [239] 36 24 87 72
a SS1 PWHT: 1000°F/8 hrs [540°C/8 hrs]
SS4 PWHT: 1150°F/8 hrs [620°C/8 hrs]
Source: Data provided courtesy of The Stoody Company.
the ease with which a crack, once initiated, will propa- Equation 23: Q = K/E
gate through the overlay. The impact toughness of over- where:
lay materials is governed primarily by their compositions
Q = thermal shock resistance, BTU/hr-ft [W/m]
and is relatively modest for the popular martensitic stain-
less steel overlays currently in use (see Table 7). K = thermal conductivity, BTU/ft-hr-ºF [W/m °C]
= yield strength at maximum exposure temperature,
7.3.5 Fire-Cracking (Thermal Fatigue) Resistance. ksi [MPa]
For rolls that are subjected to repeated heating and cool-

= thermal expansion coefficient, per ºF [ºC]
ing cycles, such as continuous caster rolls, the fire-crack-
ing resistance of the overlay is a property of concern. In E = modulus of elasticity, ksi [MPa]
general, stabilized grades of stainless steel overlays From this equation, it is evident that resistance to thermal
(such as SS4) have better fire-cracking resistance when shock cracking is directly proportional to thermal conduc-
compared to the unstabilized compositions (such as tivity and yield strength and inversely proportional to the
SS1). The need for thermal fatigue testing may be agreed thermal expansion coefficient and modulus of elasticity.
upon as a separate requirement between the supplier/user 7.3.6 Corrosion Resistance. For rolls that are
of the filler metal and the end user of the finished roll. exposed to corrosive media (such as caster rolls), the cor-
Resistance to thermal shock cracking has been quantified rosion resistance of a particular layer of the overlay mate-
by the following simplified Equation 2: rial may be of concern. Generally, the higher the carbon
content, the lower the corrosion resistance at a given
chromium level. However, alloy elements which form
carbides in preference to chromium carbides, (e.g., Mo,
V, Nb, W) can serve to prevent chromium depletion and
help retain the corrosion resistance properties. Further, in
Ì¿¾´» é stainless steel overlays, extended PWHT can sensitize
×³°¿½¬ Ì±«¹¸²»-- ±º (i.e., produce depletion of chromium in the zones imme-
Í±³» Í¬¿·²´»-- Í¬»»´ Ñª»®´¿§- diately adjacent to grain boundaries) the overlay, making
it more prone to general corrosion. Corrosion testing of
ft-lbs @ 70°F [J @ 21°C] overlays may be arranged as a separate requirement.
7.3.7 Fatigue. Wide-body rolls without support
As-Welded PWHTa between the end bearing journals can be susceptible to
fatigue. In general, the higher yield strength in stainless
SS1 5.7 [7.7] 9.7 [13.2]
SS4 4.8 [6.5] 8.2 [11.1]
3 Benedyk, J. C., D. J. Moracz, and J. F. Molloce, Thermal
a SS1 PWHT: 1000°F/8 hrs (540°C/8 hrs) Fatigue Behavior of Die Materials for Aluminum Die Casting,
SS4 PWHT: 1150°F/8 hrs (620°C/8 hrs) Trans. 6th SDCE International Die Congress, Cleveland, Ohio,
Source: Data supplied courtesy of Millcraft-SMS Services. Nov. 1619, 1970.
10
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overlays will delay fatigue crack initiation but will not preheat temperature needs to be above the martensite
slow fatigue crack propagation. start temperature (Ms temperature). The Ms temperature
may be calculated from various empirical formulae that
are available in the literature. One such formula5 is:
8. Welding Techniques and Process
Ms (°F) = 1020 630(%C) 72(%Mn) 63(%V)
Control
36(%Cr) 31(%Ni) 18(%Cu)
8.1 Overview. This section includes details of preheat and 18(%Mo) 9(%W) + 27(%Co) + 54(%Al)
interpass temperature control, welding parameters, and
postweld heat treatment. A typical form for recording weld Ms (°C) = [Ms (oF) 32] × 5/9
processing parameters is shown in Figure C.5 in Annex C. Generally, for the martensitic stainless steels and tool
steels described in Table 3, preheat temperatures used
8.2 Preheat and Interpass Temperature. The benefits
are in the 500600°F [260315°C] range. Overlay weld-
of preheat and maintaining interpass temperature are to:
ing performed with roll body temperatures below the Ms
1. Prevent underbead cracking and weld spalling. temperature will cause differential tempering in the area
Underbead cracks can occur in the heat-affected zone of the adjacent to the fusion line of subsequent overlay weld
base metal and cause spalling of the deposit or cracking of passes. This may cause uneven roll surface wear thus
the part in service. Preheat can reduce the cooling rate and resulting in a corrugated surface effect. Therefore, it is
minimize the brittleness and crack-sensitivity of the HAZ. important that the roll body temperature be kept above
2. Decrease shrinkage stresses. Shrinkage stresses build the Ms temperature until all welding has been completed.
up when weld metal contracts during cooling. Preheat The mass of the roll will determine the soaking time that
reduces the temperature difference between weld metal and is required to get the entire body of the roll to the desired
base metal thus decreases the susceptibility to cracking. preheat temperature. Figure 4 shows the soaking time
3. Reduce hydrogen damage. Preheat slows down the required for the center of the roll to reach the required
cooling rate, speeds hydrogen evolution from the roll, preheat temperature after the surface of the roll has
minimizes diffusion into the base metal, and thus reduces reached the required temperature. In the example shown
hydrogen-induced cracking. in Figure 4, for a 44 in. [1.1 m] diameter roll, the soaking
8.2.1 Determination of Preheat and Interpass time required for the roll to reach uniform temperature
Temperature.4 The determination of the required pre- through the center of the roll is 16 hours.
heat temperature is primarily governed by the base mate- The optimum way to bring the roll to preheat tempera-
rial composition of the roll. The carbon content of the ture is to use a furnace with a temperature controlled
roll material and the alloy composition have a large bear- combustion system. Alternatively, a heat shield can be
ing on the required preheat temperature. Although there built around the roll and several burners can be posi-
are numerous techniques available to determine preheat tioned below the roll. The roll has to be continuously
temperature, Figure 3 shows a simplified approach. The turned during the entire preheat cycle. Temperature indi-
carbon content of the roll is plotted on the X axis of this cating crayons, infrared sensors, or contact pyrometers
chart and the intersection of this line with the appropriate can be used to monitor the temperature.
total alloy content line gives the required preheat temper- 8.2.2 Dimensional Effects of Preheat and Interpass
ature on the Y-axis. In the example shown in Figure 3, Temperature. It should be recognized that preheating of
the rolls carbon content is 0.86% and the total alloy con- the roll will cause expansion of both its length and its
tent is 4%, resulting in a required preheat temperature of diameter. These are not entirely small effects. For exam-
675°F [360°C]. The estimated preheat temperatures ple, a roll 84 in. [2.1 m] in length at room temperature will
using this approach are shown in Table 2 for the forged increase in length by about 0.4 in. [10 mm] when pre-
rolls. For very high carbon rolls, the preheat tempera- heated to 600°F [315°C]. Likewise, a 30 in. [760 mm]
tures indicated in Figure 3 may exceed practical limits as diameter roll at room temperature will increase in diame-
far as operator discomfort and slag removal are con- ter by about 0.11 in. [2.8 mm] when preheated to the same
cerned. Wherever possible, the highest required preheat temperature. These effects have to be taken into account in
temperature should be used. designing the tooling to support the roll during welding,
In many cases when the overlay material is a martensitic and to place the welding head. Figure 5 can be used to esti-
stainless steel or a tool steel, the type of overlay material mate the increase in diameter of rolls up to 50 in. [1.27 m]
will dictate the preheat temperature. In such cases, the O.D. for preheat temperatures up to 750°F [400°C].
4 Adaptedfrom: Farmer, Howard, Steel Mill Roll Reclamation, 5 Adaptedfrom Farmer, Howard, Steel Mill Roll Reclamation,
Stoody Technical Report, Second Edition, 1975. Stoody Technical Report, Second Edition, 1975.
11
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Í±«®½»æ ß¼¿°¬»¼ º®±³ Ú¿®³»®ô Ø±©¿®¼ô Í¬»»´ Ó·´´ Î±´´ Î»½´¿³¿¬·±²ô Í¬±±¼§ Ì»½¸²·½¿´ Î»°±®¬ô Í»½±²¼ Û¼·¬·±²ô ïçéëò ß¼¿°¬»¼ ¬±
°®±ª·¼» ³»¬®·½ -½¿´» º±® °®»¸»¿¬ò
Figure 3Preheat Temperature as a Function of Carbon and Alloy Content
Í±«®½»æ ß¼¿°¬»¼ º®±³ Ú¿®³»®ô Ø±©¿®¼ô Í¬»»´ Ó·´´ Î±´´ Î»½´¿³¿¬·±²ô

Í¬±±¼§ Ì»½¸²·½¿´ Î»°±®¬ô Í»½±²¼ Û¼·¬·±²ô ïçéëò ß¼¿°¬»¼ ¬± °®±ª·¼»
³»¬®·½ -½¿´» º±® ®±´´ ¼·¿³»¬»®ò
Figure 4Required Soak Time at Temperature to Heat the Roll

Through Its Diameter as a Function of Diameter
12
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Figure 5Preheat Temperature Effect on Roll Diameter Expansion
8.2.3 Considerations for Thick Deposits. Generally, 8.3.2 The rings allow the weld to extend beyond the
buildup materials can be applied to unlimited thicknesses edge of the roll body while supporting the flux and mol-
so long as the preheat temperatures required for the base ten slag pool. They also provide an area for arc initiation
material are maintained. Stainless overlays, also, in gen- and termination, areas which are often adversely affected
eral can be applied relatively thick without the potential by slag defects and crater cracks.
for cracking. However, tool steel deposits, especially
those that exceed HRC 45, when applied in thickness 8.3.3 The run-off rings should be of sufficient thickness
greater than 1 in. [25 mm] may be susceptible to cracking to prevent burn-through during welding. They should also
and spalling during welding. This is caused by the build be selected from a grade of steel that will not adversely alter
up of excessive residual stresses due to the high yield the properties of the overlay at the edge of the roll body.
strength of these materials. An intermediate stress relief,
8.4 Welding Parameters
generally 950°1000°F [510°538°C], can sometimes be
used to alleviate this problem. The specifics of the stress
8.4.1 Typical ranges of welding parameters for
relief temperature and time should be obtained from the
3/32 in. [2.5 mm], 1/8 in. [3.2 mm], and 5/32 in. [4 mm]
manufacturer of the consumables.
tubular submerged arc welding wires are shown in Table 8.
8.3 Body Run-Off Rings The following should be noted when applying these ranges:
8.3.1 It is sometimes desirable to weld run-off or 1. When the lower end of the current range is used,
extension rings to the body before the start of the repair the lower end of the voltage range applies. Likewise,
process. The rings should be applied after the roll has when the higher end of the current range is used, the
been preheated to the start weld temperature. higher end of the voltage range applies.
13
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Ì¿¾´» è
Ì§°·½¿´ Ð¿®¿³»¬»®- º±® Ì«¾«´¿® Í«¾³»®¹»¼ ß®½ É·®»-
Diameter 3/32 in. [2.4 mm] 1/8 in. [3.2 mm] 5/32 in. [4.0 mm]
Current, Amperes 350 to 500 400 to 550 450 to 600
Volts, DCEP 25 to 29 26 to 31 27 to 32
Contact-Tip-to-Work 1 to1-1/4 in. 1-1/4 to 1-1/2 in. 1-1/4 to 1-1/2 in.

Distance [25 to 32 mm] [32 to 38 mm] [32 to 38 mm]
Deposition Rate 14 to 22 lb/h 16 to 24 lb/h 17 to 25 lb/h

[6.4 to 10 kg/h] [7.3 to 10.9 kg/h] [7.7 to 11.4 kg/h]
Source: Data supplied courtesy of The Lincoln Electric Company.
2. Deposition rates are approximate for single arc wire diameter. If the ratio of wire feed speed to travel
application. speed is held constant for a given wire diameter, then the
weld buildup will have constant cross-sectional area.
3. Using currents at the lower end of the range on the Table 9 provides wire feed speed to travel speed ratios
first layer will reduce dilution. for several wire diameters that provide approximately the
4. The welding current is the main parameter that same weld buildup cross-sectional area that works well
influences the weld deposition rate. The electrode melt- on most roll diameters. A smaller ratio may be required
off rate increases with increased current, causing for proper bead shape on small diameter rolls (less than
increased deposition rates. 10 in. [250 mm] diameter).
5. Some fabricators prefer to set wire feed speed in- 8.4.3.1 If the weld buildup cross-sectional area is
stead of setting current, because deposition rate remains too large, bead shape deteriorates because the edges tend
constant when wire feed speed remains constant, while to roll over. The weld deposit may also tend to spill off
current may vary due to variations in contact-tip-to-work the roll. If the weld buildup cross-sectional area is too
distance as the roll rotates under the welding head. small, a given total buildup requires an excessive number
of weld passes, which adds to cost.
6. At a given current, a smaller diameter wire will
have a higher deposition rate than a larger diameter wire 8.4.3.2 At a fixed ratio of wire feed speed to travel
due to higher current density applied across the smaller speed with a given electrode diameter, increasing the
cross-section of the smaller diameter wire. wire feed speed tends to increase the penetration and
dilution, and to make the bead cross section narrower
Some more specific effects are noted in detail in the and higher. Figure 6 shows this effect for a 1/8 in.
following paragraphs. [3.2 mm] wire.
8.4.2 Most Critical Variables. The most important
welding variables are wire diameter, wire feed speed
(which largely determines welding current), welding
travel speed, welding voltage and polarity, contact-tip- Ì¿¾´» ç
to-work distance (CTWD), and bead-to-bead overlap. É·®» Ú»»¼ Í°»»¼ ¬±
These variables are interrelated, so that any one or more Ì®¿ª»´ Í°»»¼ Î¿¬·±- É¸·½¸ Ð®±¼«½»
cannot be independently varied without affecting proper ¿ É»´¼ Þ«·´¼«° Ý®±--óÍ»½¬·±²¿´
settings for the others. ß®»¿ ±º ¿¾±«¬ ðòðê ·²òî Åìð ³³îÃ
8.4.3 Effects of Wire Feed and Travel Speeds. Wire Wire Diameter, 3/32 1/8 5/32 3/1
feed speed and welding travel speed for a proper bead in. [mm] [2.4] [3.2] [4.0] [4.8]
size need to be correlated. A common way to adjust
travel speed in concert with wire feed speed to obtain a Ratio of Wire Feed
8.8 5.0 3.2 2.2
Speed to Travel Speed
proper bead size without oscillation is to use a constant
ratio of wire feed speed to travel speed, depending upon Source: Data supplied courtesy of The Lincoln Electric Company.
óóÀôôÀÀÀôôôôÀÀÀÀóÀóÀôôÀôôÀôÀôôÀóóó 14
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Figure 6Overlay Beads Deposited at Wire Feed Speed (WFS) to Travel Speed
Ratio of 5 to 1, 1/8 in. [3.2 mm] Wire Diameter, 28 Volts DCEP
8.4.4 The Effect of Voltage. The tendency for a because the arc has less tendency to wander. But exces-
higher, narrower bead shape with increasing wire feed sively short CTWD can result in porosity with the tubu-
speed can be partially offset by increasing voltage, as lar metal cored wires commonly used for industrial mill
shown in Figure 7. However, higher voltage increases roll welding. In practice, CTWD between 1 and 2 in. [25
the tendency for arc blow and may cause undercut to to 50 mm] is most commonly used, with the longer
occur. Evidence of undercut can be seen in the weld CTWD favored for larger diameter wires and the shorter
made at the highest voltage level shown in Figure 7. At CTWD favored for smaller diameter wires.
wire feed speeds near the low end of the usable range for
a given wire size, DC electrode negative (DCEN) polar- 8.4.6 The Effect of Bead Placement. It is common
ity produces a higher, narrower bead, with less pene- practice to align the wire for each succeeding bead in a
tration and less dilution, than does the more commonly layer of buildup or overlay with the edge of the preced-
used DC electrode positive (DCEP) polarity. At higher ing bead. This practice results in approximately 50%
overlap of one bead on the preceding bead. The result is
wire feed speeds, this effect largely disappears, as shown
generally a nearly flat surface contour with little ten-
in Figure 8.
dency for slag entrapment. But the penetration profile
8.4.5 The Effect of Contact-Tip-to-Work Distance undulates between weld layers, and, if subsequent
(CTWD). If the wire feed speed is fixed and the voltage machining to even the surface happens to expose parts of
is fixed, then increasing the CTWD tends to reduce the interfaces between layers, preferential corrosion may
the current, penetration, and dilution. Also, at longer occur in an exposed portion of a lower layer (see 8.4.8.4
CTWD, more voltage is used in preheating the wire, so for additional discussion of this effect). If this is of con-
that less is available for the arc with a constant potential cern, it is advisable to reduce the indexing or stepover
power source. This behavior results in the bead becom- of the arc to align the wire so that it impinges entirely on,
ing somewhat narrower and higher. but near the edge, of the previous bead. This practice
results in over 60% overlap of the bead on the previous
As CTWD increases, consistent wire placement becomes bead, reduces penetration into the substrate or previous
more difficult because any curvature in the wire as it layer of weld deposit, and provides a much less undulat-
exits the contact tip results in wandering of the arc. Con- ing interface between layers. This effect is shown in
versely, short CTWD makes wire placement easier Figure 9.
15
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Figure 7Overlay Beads Deposited at 180 ipm [76 mm/sec] Wire Feed Speed,
1/8 in. [3.2 mm] Wire Diameter, Varying Voltage
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Ú·¹«®» êò Ì¸» »ºº»½¬ ·- °®»-»²¬ ¬± ¿ ´»--»® »ºº»½¬ ¿¬ ïðð ·°³ Åìî ³³ñ-»½Ã ©·®» º»»¼ -°»»¼ ¿²¼ ´¿®¹»´§ ¼·-¿°°»¿®- ¿¬ ¬¸»
¸·¹¸»® ©·®» º»»¼ -°»»¼-ò
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Figure 8Overlay Beads Deposited at Wire Feed Speed (WFS) to Travel Speed
Ratio of 5 to 1, 1/8 in. [3.2 mm] Wire Diameter, 28 Volts DCEN
16
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Figure 9Effect of Stepover at 100 ipm [42 mm/sec] Wire Feed Speed (480 A)
with 1/8 in. [3.2 mm] Wire, DCEP
17
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8.4.7 Effect of Electrode Location. The position of Lead positions of 3/4 in. [19 mm] to 1-3/4 in. [45 mm]
the electrode with respect to the roll top center (RTC) (approximately 5% of the roll diameter) are typical for
eccentric distance and eccentric angleis very important rolls up to 42 in. [1070 mm] diameter. Suggested lead
to achieve good bead shape and good slag removal. The positions for rolls ranging from 3 in. [75 mm] to >72 in.
wire should be positioned so that the molten weld pool [1830 mm] are shown in Table 10.
solidifies as it passes top center with the wire directed
The rotating surface speed is the number of inches [milli-
towards the roll center. A position too far from center
meters] passing a given point in one minute. Both the
will produce flat or concave beads with increased
speed of the roll rotation and the roll diameter affect the
chances of centerline cracking. A position too close to
surface speed. As the surface speed is increased the
center will produce narrow convex beads and undercut at
width of the weld bead decreases and the bead height
the edges. Examples of these conditions are illustrated in
increases.
Figure 10. A correct lead position produces a bead with a
slight crown and long lines of solidification which usu- A correct lead produces a bead with a slight crown and
ally exceed twice the width of the weld bead. long lines of solidification which usually are one to two
Í±«®½»æ ß¼¿°¬»¼ º®±³ Ú¿®³»®ô Ø±©¿®¼ô Í¬»»´ Ó·´´ Î±´´ Î»½´¿³¿¬·±²ô Í¬±±¼§ Ì»½¸²·½¿´ Î»°±®¬ô Í»½±²¼ Û¼·¬·±²ô ïçéëò
Figure 10Effect of Electrode Position on Bead Shape, Slag Spillage, and Flux Spillage
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Electrode Displacement (d)
Diameter of Base Metal Surface Ahead of Roll Top Center (RTC)
in. mm in. mm
3 to 18 75 to 460 3/4 to 1 19 to 25
18 to 36 460 to 910 1-1/4 to 1-1/2 32 to 38
36 to 42 910 to 1070 1-1/2 to 1-3/4 38 to 44
42 to 48 1070 to 1220 1-3/4 to 2 44 to 51
48 to 72 1220 to 1830 2 to 2-1/2 51 to 64
over 72 over 1830 3 75
Note: The electrode should be perpendicular to the roll surface regardless of displacement.
Source: Data supplied courtesy of The Lincoln Electric Company. Table 10 figure adapted from The Lincoln Electric Company.
18
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times the width of the weld bead. Examples of these con- 4. Electrode Polarity: DCEN reduces dilution when
ditions are shown in Figure 11. compared to DCEP at the same current level. This effect
is important near the low end of the wire feed speed
8.4.8 The Effect of Dilution. The composition of the (current) range for which a given electrode diameter is
overlay on the working surface is dependent on the suitable, but it is much less important at higher wire feed
degree of dilution resulting from the welding process. speeds. However, DCEN may limit travel speed and dep-
The degree of dilution governs the properties of the over- osition rate due to the tendency for undercut. Also
lay regarding hardness, strength, and corrosion resis- DCEN deposits may be more prone to porosity due to
tance. The degree of dilution determines the number of lower resistance heating of the wire before it reaches the
layers required to achieve true weld metal composition. arc.
Generally, low dilution is preferred when surfacing rolls
so as to achieve the desired properties of the overlay as 5. Stepover: Increasing stepover (i.e., the distance the
quickly and economically as possible. wire is indexed relative to the previous deposit before
depositing the next bead) increases dilution.
8.4.8.1 Some of the factors and how they affect
dilution are: 6. Layers of Weld: The effect of base metal dilution is
reduced as the number of layers of weld is increased (see
1. Preheat/Interpass Temperature: Higher preheat/ Table 11).
interpass temperatures result in greater dilution.
7. Electrode Diameter: A large diameter electrode
2. Welding Current: Higher current (wire feed speed) reduces dilution as compared to a smaller diameter elec-
increases dilution. trode at the same current levels.
3. Travel Speed: Slower welding speeds reduce dilu- 8. Number of Electrodes: Twin electrodes reduce
tion over the range of travel speeds normally used in roll dilution as compared to a single electrode at the same
welding. deposition rate.
Figure 11Effect of Lead Position on Bead Solidification Lines
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º±® ¿ Ú´«¨óÉ·®» Ý±³¾·²¿¬·±² Ð®±¼«½·²¹ ïíû Ý® ß´´óÉ»´¼óÓ»¬¿´
% Cr for Each Layer Number
% Dilution Layer 1 Layer 2 Layer 3 Layer 4 Layer5 Layer 6
20% 10.40 12.48 12.90 12.98 13.00 13.00

30% 9.10 11.83 12.65 12.89 12.97 12.99

40% 7.80 10.92 12.17 12.67 12.87 12.95
50% 6.50 9.75 11.38 12.19 12.59 12.80
60% 5.20 8.32 10.19 11.32 11.99 12.39
19
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9. Oscillation Speed and Voltage: Both variables in a surface of varying composition which becomes sus-
should be optimized as a function of the welding proce- ceptible to preferential corrosion attack in the lower
dures to create a uniform weld bead with consistent qual- alloyed second layer.
ity. Both variables may slightly affect penetration and
dilution, but their effect on weld bead contour, width, In continuous caster rolls of steel mills, this condition
and quality is more dramatic. leads to the so-called dark bands of preferential corro-
sion on the roll surface which are often (mistakenly)
10. Contact-Tip-to-Work Distance (CTWD): Increasing attributed to heat-affected zone damage. Reducing step-
CTWD reduces dilution. over so that the overlap of a bead on the previously
8.4.8.2 SAW, particularly with the DC electrode deposited weld metal is about 60% to 70% will markedly
positive (DCEP) polarity, is usually a high dilution weld- reduce the undulations of the interface between layers
ing process. In SAW-DCEP welding, dilution may and reduce the susceptibility to this preferential corrosion.
approach or exceed 50%. If a flux/wire combination is 8.4.8.5 Another approach for dealing with dilution
chosen based upon a specific desired all-weld-metal to reduce the number of layers needed to achieve a par-
composition, it is important to consider what the compo- ticular minimum alloy content in a given number of
sition of various layers of weld overlay will be. For layers (often three layers), is for the wire manufacturer to
example, if a flux/wire combination is used which pro- over-alloy a tubular wire to accommodate appreciable
duces an all-weld-metal composition of 13% Cr, the dilution in the specified number of layers under the spec-
chromium content of each overlay layer may be calcu- ified welding conditions.
lated as a function of dilution to make an overlay on a
chromium-free substrate as illustrated in Table 11. 8.5 Considerations Specific to Journal Repair,
Buildup, or Overlay
8.4.8.3 Obtaining a 12% Cr content in the third
layer of overlay requires that the dilution be limited to a 8.5.1 Butter Layers. When overlaying rolls of rela-
little more than 40% with this hypothetical flux/wire tively high carbon content (typically 1.0% and above), it
combination. Since the manufacturer(s) of the flux and is advisable to deposit a butter layer with a low carbon
wire have no control over the dilution or number of lay- steel filler metal that has high compressive strength. This
ers that will be deposited by the welder, the normal spec- will prevent the pickup of excessive amounts of carbon
ification for weld deposit applies to undiluted weld from the base material into the overlay which can lead to
metal with a particular wire and flux. Undiluted may embrittlement and spalling in service. One such butter
mean four, five, or six layers of weld metal. This is a layer composition is BU3 shown in Table 3. It is critical
matter which should be clearly understood and agreed to that correct procedures with regard to preheat and inter-
between the Manufacturer(s) and the user. If deposit pass temperatures are followed when overlaying high
composition other than undiluted weld metal is specified, carbon content rolls.
the required number of layers should be specified along
with clearly defined welding conditions, including wire 8.5.2 Journal Buildup and Repair
feed speed, voltage, polarity, travel speed, electrode
extension, and stepover. 8.5.2.1 Journals or bearing seat areas can be built
up or weld repaired by, but not limited to, the SAW,
8.4.8.4 Reducing the stepover, so that the arc FCAW, GMAW, and SMAW processes. In all cases, a
impinges primarily on previously deposited weld metal low hydrogen welding practice should be utilized.
of the same layer, can be used to reduce dilution, as com-
pared to the normal stepover where the arc impinges on 8.5.2.2 Typical welding consumables consist of
the toe of the previous weld bead in a given layer. mild steel and low-alloy steel grades. The selection is
generally based upon hardness as a function of PWHT. A
Changing the stepover or indexing of the welding head suitable wire/flux combination should be selected to
relative to the previously deposited metal, besides allow qualification of the welding procedure for unlim-
directly influencing dilution, also influences the shape of ited thickness. The consumables should produce good
the interface between layers of weld metal. Generally, a weldability, sound weld deposit, and postweld-heat-
stepover that produces 50% overlap of the previously treated properties that are comparable to the base material.
deposited metal will produce a pronounced undulation of
the interface between layers. Often, three layers of weld 8.5.2.3 Journal areas requiring repair should be
overlay are deposited, and the third layer will have sig- machined at no less than 1/16 in. [1.6 mm] radially
nificantly different composition than the second layer below finish size. The repair welding should not termi-
(see Table 11). Depending on the final machining depth, nate in the fillet radius area that joins the journal to the
the peaks of the second layer may be exposed, resulting body shoulder. The weld repair should terminate either
20
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prior to the fillet radius area or be welded continuous At times, areas of journals that are final-machined sur-
through the radius onto the shoulder. faces need to be protected to prevent scale formation dur-
ing postweld heat treatment. It is recommended that
8.5.2.4 The journal areas to be welded should be finished journals be protected with a suitable anti-scaling
preheated to the minimum recommended preheat tem- coating that is service-rated for the specified postweld
perature of the base material or welding consumable. heat treatment temperature.
Journals can be locally preheated or furnace preheated.
The entire journal area should be preheated and main- 8.5.3 Overlay
tained at or above the minimum recommended tempera-
ture prior to any weld buildup or buttering. The preheat 8.5.3.1 The overlay layers are most commonly
and interpass temperature should be sufficient to prevent deposited by the SAW process or the FCAW self-shielded,
cracking. A soak time is needed to allow the journal to be open arc process, but other processes may be used.
heated through its entire cross section and minimize tem-
perature differentials between the surface and interior. 8.5.3.2 A wire/flux combination should be selected
Thermal shock may cause cracking of the base material. to provide good weldability, a sound weld deposit, and
when used, postweld-heat-treatment properties that meet
8.5.2.5 The buildup process consists of overlaying the service requirements or the customer specifications.
a journal prior to surfacing.
8.5.3.3 A minimum preheat and interpass tempera-
8.5.2.6 A buttering process consists of creating a ture range should be maintained throughout the welding
transitional zone between base material and buildup process. The preheat and minimum interpass tempera-
and/or between buildup and overlay. Buttering is intended tures are usually above the martensite start temperature
to provide chemical compatibility between the overlay (Ms) to avoid premature transformation of the weld metal
and the base metal, thereby improving weldability. that could lead to cracking. Maintaining the proper inter-
pass temperature range also helps in controlling bead
8.5.2.7 Undercut areas should be prepared so that shape, which helps to reduce the chance of slag entrap-
each included angle and the weld joint are a minimum of ment. Not maintaining proper preheat can result in non-
15° with a radius at the root. This weld joint preparation uniform hardness and mechanical properties, and may
is intended to provide good sidewall tie-in and to avoid result in cracking.
slag entrapment.
8.5.3.4 The number of weld layers should be
8.5.2.8 A proper welding technique should be uti-
predetermined by customer specifications and/or final
lized to maintain an even and concentric buildup. Proper
thickness requirements.
welding techniques should provide a relatively flat sur-
face prior to surfacing that will result in a consistent 8.5.3.5 On multiple-head welding systems, atten-
overlay composition and thickness. It may be necessary tion should be paid to the tie-in area of the roll. A tie-in
to machine the buildup surface prior to final overlay if area is caused by the crossover or overlapping of the
the buildup layers are not uniform or display excessive welding beads when multiple welding heads are used.
hills and valleys. The deposit of the last rotation of one bead must tie in
A welding technique that utilizes multiple arcs or oscilla- completely to the deposit of the first rotation of another
tions as compared to stringer beads will increase the heat bead. When bead placement is not optimal, slag entrap-
input to the work piece. This increase in heat input can ment or lack of fusion may result at the tie-in area.
affect the mechanical properties of the base material and
8.5.3.6 In circumferential weld overlaying, the lon-
increase the potential for distortion.
gitudinal movement of the welding head can be accom-
8.5.2.9 A postweld heat treatment is recommended plished by stepover or spiral indexing techniques
after welding. A slow cool after weld repair is necessary (see Figure 12). A stepover is the longitudinal distance
prior to heat-treating. Cooling rates less than 50°F moved by the welding head after each weld bead is
[30°C] per hour are typically used. For critical parts, the deposited over the entire 360° of the roll circumference.
journals are sometimes wrapped in ceramic fiber blan- In the spiral indexing technique, the welding head moves
kets to further reduce the cooling rate. continuously along the longitudinal axis of the roll creat-
ing a spiral bead. In either case, the percent of overlap
Because a large depth of repair can cause a high restraint should be controlled to control dilution, maintain proper
situation that may lead to cracking, it may be necessary bead profile, ensure tie-in to previous bead, and avoid
to perform intermediate postweld heat treatment(s) in slag entrapment. It is recommended with multiple layers
cases of highly restrained welds. of overlay (when using this technique) that the bead
21
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Figure 12Stepover Techniques
placement and stepover area be offset approximately 1/2 just referred to as temper treatment and normally
bead width from the previous bead. takes place between 900°F and 1150°F [480°C and
620°C].
8.5.3.7 A postweld heat treatment is typically uti-
lized. In postweld heat treatment, the first step is a slow 8.6.2 Typical heat treatment for welded rolls involves
cool process in which the roll is cooled after welding allowing the rolls to slow cool from the welding temper-
down to and below the martensite finish temperature ature at a rate less than 100°F/h [55°C/h] to approxi-
(Mf). This temperature can be typically 210°F [100°C]. mately 100°F [55°C] below the overlay materials
The Mf temperature depends on the composition of the martensite start (Ms) temperature (see 8.2.1). The roll is
weld metal and should be provided by the consumable then held at that temperature for several hours to allow
supplier. The next step is to uniformly heat the roll at a the entire roll to reach a uniform temperature. The roll is
controlled rate to a predetermined tempering tempera- then gradually heated to 900°F to 1150°F [480°C to
ture. The roll is then uniformly maintained at this tem- 620°C] for tempering. The heating rates should be slow
perature for a specific soak time to achieve the desired enough (50°F/h to 150°F/h [30°C/h to 90°C/h]) so as not
mechanical properties. The postweld heat treatment of to exceed the tempering temperature. The tempering
the roll should be done at a temperature which is below time depends on the roll diameter and the desired hard-
the original tempering temperature of the base material ness level but is typically 1/2 hour per in. [25 mm] of the
to avoid changing the mechanical properties of the base roll diameter. Cooling from the tempering temperature
material. The supplier of the weld consumables should should also be slow (less than 200°F/h [110°C/h]) to at
be contacted for specific temper response properties of least 500°F [260°C].
the overlay to assure that the desired or specified proper-
ties can be achieved. Tempering heat treatments reduce the residual stresses
introduced by the welding thermal cycle in the overlay
8.5.3.8 If the overlay is used in the as-welded
materials. PWHT also reduces the weld metal hardness
condition, a separate heat treatment may be needed
and improves its ductility. As a result of the tempering
for the buildup material or journal repair prior to
treatment, a more desirable combination of strength,
overlay.
hardness, and toughness can be obtained for the overlay
8.6 Postweld Heat Treatment material.
8.6.1 Overview. There are different kinds of 8.6.3 In addition to the tempering time and tempera-
postweld-heat-treatments (PWHT) including annealing, ture, the hardness of the overlay material also depends on
normalizing, stress relieving, and tempering. Annealing the alloy present in the weld metal. Alloying the weld
and normalizing are performed at a temperature above deposit with molybdenum, vanadium, niobium or tung-
the critical (re-austenitizing) temperature while stress sten helps to retain the hardness level after exposure to a
relieving and tempering are performed at a temperatures given tempering temperature. For example, the SS3 and
below the critical temperature. The roll re-manufacturing SS4 have an equal or lower as-welded weld metal hard-
industry generally concentrates on using the sub-critical ness than that of SS1 (Table 3), but after tempering the
heat treatments and makes no distinction between the SS3 and SS4 deposits become appreciably harder than
stress relieving and tempering processes. It is often the SS1 deposit (Table 5).
22 óóÀôôÀÀÀôôôôÀÀÀÀóÀóÀôôÀôôÀôÀôôÀóóó
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8.6.4 In some rolls overlaid with tool steels, more than 9.2.1.1 Level 1 Qualification. Level 1 procedure
one tempering cycle may be needed to produce the qualification consists of a plate test as shown in Figure 13.
desired properties. This process may be required because The purpose of this level of qualification is to determine
the higher alloyed tool steel overlay materials may form the suitability for use of a given combination of consum-
additional martensite during the cooling phase of the first ables before undertaking extensive procedure qualifica-
tempering cycle. It is therefore often recommended to tions. This level of procedure qualification can be utilized
perform a second PWHT to temper the freshly formed for journal repair, body buildup, or body overlaying. The
martensite and produce more uniform properties. welding parameters for a plate test quite often do not rep-
resent the parameters required to weld a rotating roll of
8.6.5 For accurate heat treatment temperature con- varying diameter. Therefore the results of Level 1 qualifi-
trols, calibrated pyrometric equipment, such as thermo- cation are only an approximation for roll procedure quali-
couples, should be used to verify that the specified fication. While Level 1 qualification may be used to
temperature and time at temperature are achieved. Chart qualify procedures for journal repair and buildup, it is not
recorders may also be necessary for documentation and recommended to use Level 1 qualifications to approve the
quality control purposes. procedure for roll overlay. It is recommended that at least
five layers of weld overlay be deposited for testing.
9.2.1.2 Level 2 and 3 Qualifications. Level 2 and

3 procedure qualifications consist of a roll/cylinder test
9. Procedure Qualification and Tests as shown in Figure 14. The purpose of these qualifica-
9.1 Procedure Qualifications (WPS). There are three tions are to impose more stringent requirements on the
recommended levels for procedure qualification. The contractor and to be able to test and qualify both the pro-
applicable levels should be reached by agreement cedures and material properties that closely represent the
between the buyer and the contractor. These recom- actual welded roll. If the procedure qualification is to be
mended levels are shown in Table 12. performed for overlays where buildup and buttered lay-
ers are used, it is recommended that the qualification be
9.1.1 WPS Forms. Regardless of which level or lev- performed whereby these layers are deposited before
els are chosen, there should be a Welding Procedure application of the overlay.
Specification (WPS) for each welding process that lists
essential or nonessential variables. A recommended form 9.3 Type of Tests Required. The necessary tests that
for the WPS is given in Annex C. For a list of essential may be performed to qualify a welding procedure are
and nonessential variables see Table 13. given in Table 12.
9.3.1 Chemical Composition Analysis. A chemical
9.1.2 Procedure Requalification. Changes may be
made in the nonessential variables to suit production composition analysis should be obtained from the test
requirements without requalification of the procedure coupon. In the case of the plate test (Level 1), the analy-
provided such charges are documented in either an sis represents the all-weld metal composition. Samples
amendment to the original WPS or a new WPS. A should be taken as close to the top surface as possible to
change in any essential variable should require the con- minimize dilution from the base metal. In the case of the
tractor to notify the buyer to determine if and how roll/cylinder test (Levels 2 and 3) the test can be at the
requalification is to be performed. finished overlay thickness specified by the buyer. Where
the overlay radial thickness is high (typically > 5/8 in.
9.2 Procedure Qualification Record (PQR). The spe- [16 mm]), it is not necessary to deposit the entire thick-
cific facts involved in qualifying a WPS should be ness on the test roll. Thinner overlays than required for
recorded in a form called a PQR, which should document actual roll applications can be used for qualification pur-
the essential variables of the specific welding process or poses as long as the overlay is of sufficient thickness to
processes, as listed in Table 13, and the test results. Rec- avoid dilution from the base metal.
ommended forms are given in Annex C.
9.3.2 Hardness. Hardness testing is to be performed
9.2.1 WQTR Forms. If the welding process or pro- after PWHT (if applicable). For the plate test, the hard-
cesses employed are automatic or semi-automatic, then ness readings should be taken on the machined surface of
procedure qualification will normally suffice for welder the weld metal. For the roll/cylinder test, the hardness
or operator qualification. If the welding process or pro- readings should be taken at the maximum and minimum
cesses employed are manual, then welder qualification is overlay thicknesses specified by the buyer. The recom-
recommended. Recommended forms for Welder Qualifi- mended locations of the hardness impressions are shown
cation Test Record (WQTR) are given in Annex C. in Figure 15.
23
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Í¿³°´» Ì§°»- ª-ò Ï«¿´·º·½¿¬·±² Ô»ª»´-
Level 1 Level 2 Level 3
Plate X
Roll/Cylinder Optional X X
Chemical X X X
Hardness X X X
Soundness X X X
CVN Optional X X
Tensile Optional X X
Thermal Fatigue Optional
Hot Hardness Optional
Temper Response Optional X
Microstructure Optional
Temper Embrittlement Optional
Corrosion Optional
Wear Resistance Optional
Chemistry Profile by Depth Optional X
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É»´¼·²¹ Ð®±½»-- Ê¿®·¿¾´»-
Welding Process
SAW FCAW GMAW

Variable
No. Variable Aa Bb Cc Aa Bb Cc Aa Bb Cc
Joint Variables
(1) Groove Design X X X
(2) ± Backing
(3) Backing (complete joint penetration welds) X X X
(4) + Backing
(5) > Fit-up Gap
(6) Penetration
Material Variables
(1) Group Number X X X
(2) > Thickness of 5/8 in. [16 mm] over Max. Qualified X X X
(3) t > Thickness Qualified X X X
(4) > Pass Thickness Limit X X X
(5) > Base Metal Thickness (GMAW-S) X
(6) M-Number X X X
(7) M-Number from 9-A to 9-B X X X
Filler Metal Variables
(1) Cross-Section or Wire Speed
(2) < t or Chemical Composition
(3) Size of Filler Metal
(4) F-Number X X X
(Continued)
24
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Ò± ®»°®±¼«½¬·±² ±® ²»¬©±®µ·²¹ °»®³·¬¬»¼ ©·¬¸±«¬ ´·½»²-» º®±³ ×ØÍ Ò±¬ º±® Î»-¿´»
Ì¿¾´» ïí øÝ±²¬·²«»¼÷
É»´¼·²¹ Ð®±½»-- Ê¿®·¿¾´»-
Welding Process
SAW FCAW GMAW

Variable
Filler Metal Variables (Contd)

(5) Chemical Composition (i.e., A-No.) X X X
(6) > Diameter X X X
(7) ± Supplementary Deoxidizers
(8) Flux Classification X
(9) Chemical Composition by > or < of Alloy Flux X
(10) Size of Flux Particles X
(11) Filler Metal Classification X X X X X X
(12) ± Consumable Insert
(13) ± Filler Metal
(14) Flux Type or Chemical Composition
(15) Filler Metal and Flux Brand Named X X
(16) Wire to Strip or Vice Versa
(17) Guide Type
(18) Method of Addition
(19) Chemical Composition
(20) FCAW-S to FCAW-G or vice versa X
(21) ± Supplemental Filler Metal X X X
(22) ± Supplemental Powder Filler Metal X
(23) > Supplemental Powder Filler Metal X
(24) Chemical Composition by > or < Supp. Powder X
Positions
(1) + Position X X X
(2) Position to Vertical X X
Preheat
(1) < 100°F [38°C] X X X
(2) Temperature X X X
(3) > Maximum Interpass Temperature X X X
Postweld Heat Treatment
(1) PWHT X X X
(2) ± Solution PWHT for M-8 Base Metal X X X
Gas
(1) ± Trailing or Chemical Composition
(2) Gas or Gas Mixture X X
(3) Flow Rate X X
(4) Chemical Composition and Flow Rate
(Continued)
25óóÀôôÀÀÀôôôôÀÀÀÀóÀóÀôôÀôôÀôÀôôÀóóó
Ý±°§®·¹¸¬ ß³»®·½¿² É»´¼·²¹ Í±½·»¬§

Ð®±ª·¼»¼ ¾§ ×ØÍ «²¼»® ´·½»²-» ©·¬¸ ßÉÍ
Ò± ®»°®±¼«½¬·±² ±® ²»¬©±®µ·²¹ °»®³·¬¬»¼ ©·¬¸±«¬ ´·½»²-» º®±³ ×ØÍ Ò±¬ º±® Î»-¿´»
Ì¿¾´» ïí øÝ±²¬·²«»¼÷
É»´¼·²¹ Ð®±½»-- Ê¿®·¿¾´»-
Welding Process
SAW FCAW GMAW

Variable
Gas (Contd)
(5) + Backing Gas or Rate or Composition X
(6) Environmental
Electrical Characteristics
(1) Current Type (I), Polarity, > Heat input X X X
(2) Mode of Metal Transfer X X
(3) ± Pulsed Current
(4) ± 15% Current or Voltage
(5) Beam Parameters (EBW)
(6) Pulsing Frequency
(7) Current Type or Polarity, or ± I or V X X X
Technique
(1) Current Type (I), Polarity, > Heat input X X X
(2) Bead Technique X X X

(3) Method of Back Gouging X X X
(4) Oscillation X X X
(5) Multiple Pass to Single Pass per Side X X X
(6) Single to Multiple Electrode, or Vice Versa X X X
(7) Chamber
(8) Melt-in to Keyhole or Vice Versa
(9) ± Retainers X X X
(10) Gun Angle
(11) Electrode Spacing X X X
(12) Type or Model of Equipment
(13) > Absolute Pressure (Vacuum)
(14) Filament Configuration
(15) + Wash Pass
(16) 1 to 2 Sides or Vice Versa
(17) < Travel Speed over 10% X X X
a The symbol A when marked with an X signifies that the given variable is essential and should be documented in both the PQR and WPS. If this
variable is changed from that qualified (i.e., documented on the PQR), the WPS should be requalified.
b The symbol B when marked with an X signifies that the given variable is essential only when fracture toughness is a requirement. When fracture
toughness is a requirement, these variables are the same as those in Note a.

c The symbol C when marked with an X signifies that the given variable is nonessential and may be changed on the WPS without requalification, but
the WPS should be revised.

d Unless the consumables are classified under AWS specifications.
Legend:
Change Welding Processes
< = Decrease t = Thickness SAW: Submerged Arc Welding
+ = Addition = Uphill FCAW: Flux Cored Arc Welding
= Deletion = Downhill GMAW: Gas Metal Arc Welding
> = Increase
26
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Ð®±ª·¼»¼ ¾§ ×ØÍ «²¼»® ´·½»²-» ©·¬¸ ßÉÍ
Ò± ®»°®±¼«½¬·±² ±® ²»¬©±®µ·²¹ °»®³·¬¬»¼ ©·¬¸±«¬ ´·½»²-» º®±³ ×ØÍ Ò±¬ º±® Î»-¿´»
Figure 13Basic Bead on Plate Sample for Level 1 Qualification
Figure 14Roll Cylinder Sample for Level 1, 2, or 3 Qualification
Ò±¬»-æ
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îò Î±½µ©»´´ •ÝŒ ¸¿®¼²»-- ·³°®»--·±²- ¿®» ¬± ¾» ¬¿µ»² ¿¬ ¬©± ´±½¿¬·±²-æ
¡ ß´±²¹ ¿ ê ·²ò Åïëð ³³Ã ´·²» ´±½¿¬»¼ ±² ¬¸» º·²·-¸ ³¿½¸·²»¼ -«®º¿½»ô ¿¬ ïñî ·²ò Åïí ³³Ã ·²¬»®ª¿´-ò
¡ ß´±²¹ ¿ ê ·²ò Åïëð ³³Ã ´·²» ´±½¿¬»¼ ðòîðð ·²ò Åë ³³Ã ¾»²»¿¬¸ ¬¸» º·²·-¸ ³¿½¸·²»¼ -«®º¿½»ô ¿¬ ïñî ·²ò Åïí ³³Ã ·²¬»®ª¿´-ò
Í±«®½»æ Ú·¹«®» -«°°´·»¼ ½±«®¬»-§ ¬¸» Ë²·¬»¼ Í¬¿¬»- Í¬»»´ Ý±®°±®¿¬·±²‰Ì»½¸²·½¿´ Ý»²¬»®ò
Figure 15Roll Qualification TestsQualification of Hardfacing

Location of Rockwell Hardness Test Samples 1A1, 2B1, 2C1
27
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9.3.3 Soundness. The weld overlay surface should be definition of the weld metal and heat-affected zone
examined by the Magnetic Particle Inspection method (HAZ). Visual examination of the cross section of the
(ASTM E 709, Practice for Magnetic Particle Examina- weld metal should show complete fusion. The weld
tion), providing the material is magnetic. If the material metal and HAZ should be free of cracks. The recom-
is nonmagnetic, then examination is typically by the mended locations of the etch test samples are shown in
Liquid Penetrant Inspection Method (ASTM E 165, Figures 15 and 16.
Standard Test Method for Liquid Penetrant Examina-
tion). Magnetic particle or liquid penetrant testing should 9.3.4 Impact. Charpy V-notch samples can be
be performed after machining the surface of the overlay. removed (minimum 3 samples, see Figures 17 and 18) to
test notch toughness. Test procedures and apparatus for
One face of a cross-section coupon should be ground Charpy V-Notch testing should conform to the require-
smooth and etched with a suitable etchant to give a clear ments of AWS B4.0, Standard Methods for Mechanical
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ø·÷ ×ßï ·- ¬± ¾» «-»¼ º±® Î±½µ©»´´ ¸¿®¼²»-- ¬»-¬·²¹ øÚ·¹«®» ïë÷ ¿²¼ ½¸»³·½¿´ ¿²¿´§-·-ò
ø··÷ ïÞï ·- ¬± ¾» «-»¼ º±® ³»¬¿´´±¹®¿°¸·½ -¿³°´»- ¿²¼ ³·½®±¸¿®¼²»-- ¬»-¬·²¹ò
ø···÷ îÞï ·- ¬± ¾» «-»¼ º±® Î±½µ©»´´ ¸¿®¼²»-- ¬»-¬·²¹ øÚ·¹«®» ïë÷ò
ø·ª÷ îÝï ·- ¬± ¾» «-»¼ º±® Î±½µ©»´´ ¸¿®¼²»-- ¬»-¬·²¹ øÚ·¹«®» ïë÷ ¿²¼ ½¸¿®¿½¬»®·¦¿¬·±² ±º ·²¬»²¬·±²¿´ ¸¿®¼º¿½·²¹ ·²¬»®®«°¬·±²-ò
íò ïßî ·- ¬± ¾» ®»³±ª»¼ ¿²¼ -»½¬·±²»¼ ·²¬± ¬»² øïð÷ °·»½»-ô ï ·²ò Åîë ³³Ã ´±²¹ô ï ·²ò Åîë ³³Ã ©·¼» ¿²¼ ï ·²ò Åîë ³³Ã ¼»»°ò Ì¸»-» -¿³°´»-
©·´´ ¾» «-»¼ º±® ¬»³°»® ®»-·-¬¿²½» ¬»-¬·²¹ò
ìò ïßí ¿²¼ ïÞí ¿®» ¬± ¾» ®»³±ª»¼ ¿- -»½¬·±²- ê ·²ò Åïëð ³³Ã ´±²¹ô ï ·²ò Åîë ³³Ã ©·¼» ¿²¼ ï ·²ò Åîë ³³Ã ¼»»° º±® ½±®®±-·±² ¬»-¬·²¹ò
ëò ïÞî ·- ¬± ¾» ®»³±ª»¼ ¿- ¿ -»½¬·±² ê ·²ò Åïëð ³³Ã ´±²¹ò î ·²ò Åëð ³³Ã ©·¼» ¿²¼ î ·²ò Åëð ³³Ã ¼»»° º±® ¸±¬ ¸¿®¼²»-- ¬»-¬·²¹ò
êò îÞî ·- ¬± ¾» ®»³±ª»¼ ¿²¼ ½«¬ ·²¬± ¬©± øî÷ °·»½»-ô í ·²ò Åéë ³³Ã ´±²¹ô í ·²ò Åéë ³³Ã ©·¼» ¿²¼ î ·²ò Åëð ³³Ã ¼»»° º±® º·®»ó½®¿½µ ¬»-¬·²¹ò
éò îÝî ·- ¬± ¾» ®»³±ª»¼ ¿²¼ ½«¬ ·²¬± ¬©± øî÷ °·»½»-ô í ·²ò Åéë ³³Ã ´±²¹ô í ·²ò Åéë ³³Ã ©·¼» ¿²¼ î ·²ò Åëð ³³Ã ¼»»° º±® º·®»ó½®¿½µ ¬»-¬·²¹ò
Í±«®½»æ Ú·¹«®» -«°°´·»¼ ½±«®¬»-§ ¬¸» Ë²·¬»¼ Í¬¿¬»- Í¬»»´ Ý±®°±®¿¬·±²‰Ì»½¸²·½¿´ Ý»²¬»®å ¿¼¿°¬»¼ ¬± ¿¼¼ ³»¬®·½ ¼·³»²-·±²-ò

Sample Layout and General Description
28
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¾±¼§ ½±³°±-·¬·±² ¿²¼ ³»½¸¿²·½¿´ °®±°»®¬§ -°»½·º·½¿¬·±²-ò
îò Ì¸» ³¿½¸·²»¼ ¹®±±ª» ·- ¬± ¾» ®»°¿·®»¼ «-·²¹ ¿² ¿°°®±°®·¿¬» ¾«·´¼«° ³¿¬»®·¿´ ¿²¼ ©»´¼ ¬»½¸²·¯«» ¿- ¼±½«³»²¬»¼ ·² ¬¸» ÉÐÍò
íò ßº¬»® ¬¸» ¾«·´¼«° ³¿¬»®·¿´ ¸¿- ¾»»² ¿°°´·»¼ ©·¬¸·² ¬¸» ¹®±±ª» ¿®»¿ô ¸¿®¼º¿½·²¹ ¿´´±§ ·- ¬± ¾» ¿°°´·»¼ ¿½®±-- ¬¸» »²¬·®» ®±´´ -«®º¿½» «-·²¹
¿°°®±°®·¿¬» ³¿¬»®·¿´- ¿²¼ ©»´¼ ¬»½¸²·¯«»- ¿- ¼±½«³»²¬»¼ ·² ¬¸» ÉÐÍò
ìò Ì¸®»» ·²¬»²¬·±²¿´ ¸¿®¼º¿½·²¹ ©»´¼ ·²¬»®®«°¬·±²- -¸±«´¼ ¾» °»®º±®³»¼ ¿¬ ´±½¿¬·±² ÝóÝæ ï÷ô ©·¬¸·² ¬¸» ·²·¬·¿´ ´¿§»® ¿¬ î ·²ò Åëð ³³Ã º®±³ ¬¸»
´»º¬ »¼¹»ô î÷ ©·¬¸·² ¬¸» ³·¼¼´» ´¿§»® ¿¬ í ·²ò Åéë ³³Ãô ¿²¼ í÷ ¬¸» º·²¿´ ´¿§»® ¿¬ ì ·²ò Åïðð ³³Ã º®±³ ¬¸» ´»º¬ »¼¹» ±º ¬¸» ¬»-¬ ®±´´ò ß´´ ±¬¸»®
-¬¿®¬-ñ-¬±°- -¸±«´¼ ¾» ¼±²» ²»¿® ´±½¿¬·±² ßóßò
ëò Ë°±² -«½½»--º«´ ½±³°´»¬·±² ±º ¬¸» ©»´¼·²¹ °®±½»--»- ¿²¼ °±-¬ó©»´¼ ¸»¿¬ ¬®»¿¬³»²¬ô ¬¸» ´»º¬ -·¼» øç ·²ò Åîîë ³³Ã÷ ±º ¬¸» ¬»-¬ ®±´´
-¸±«´¼ ¾» -¿© ½«¬ º®±³ ¬¸» ®·¹¸¬ -·¼» øé ·²ò Åïéë ³³Ã÷ ¿¬ ¬¸» ·²¼·½¿¬»¼ ´±½¿¬·±²ô ¬± º¿½·´·¬¿¬» ¯«¿´·º·½¿¬·±² ¬»-¬·²¹ ±º ¬¸» ¸¿®¼º¿½·²¹ ¿²¼
¾«·´¼«° ³¿¬»®·¿´-ô ®»-°»½¬·ª»´§ò
Í±«®½»æ Ú·¹«®» -«°°´·»¼ ½±«®¬»-§ ¬¸» Ë²·¬»¼ Í¬¿¬»- Í¬»»´ Ý±®°±®¿¬·±²‰Ì»½¸²·½¿´ Ý»²¬»®å ¿¼¿°¬»¼ ¬± ¿¼¼ ³»¬®·½ ¼·³»²-·±²-ò
Figure 17Roll Buildup Qualification Tests

Sample Roll Configuration Prior to Welding
29
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¬± ¾» -»²¬ ¬± ¬¸» Ð«®½¸¿-»®Ž- ¬»-¬·²¹ ´¿¾±®¿¬±®§ò Ï«¿¼®¿²¬ ì ·- º±® ®»¬»²¬·±² ¾§ ¬¸» ª»²¼±®ò
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-»½¬·±²- -¸±«´¼ ¾» ³¿½®±»¬½¸»¼ ¿²¼ ½¸»½µ»¼ º±® ©»´¼ ¬¸·½µ²»-- ¿²¼ ½´»¿²´·²»--ò
íò ß ³·²·³«³ ±º ¬©± øî÷ ¬»²-·´» -¿³°´»- ¿®» ¬± ¾» ®»³±ª»¼ º®±³ ¬¸» •ÞŒ -·¼» ±º Ï«¿¼®¿²¬ ïò Ì¸» ®»¼«½»¼ -»½¬·±² ±º »¿½¸ -¿³°´» -¸±«´¼
¾» ´±½¿¬»¼ ©·¬¸·² ¬¸» ¾«·´¼«° ®»¹·±² ±º ¬¸» ¬»-¬ ®±´´ò Ì¸» ¬»²-·´» -¿³°´»- -¸±«´¼ ½±²º±®³ ¬± ßÉÍ Þìòð º±® ¿ ðòëðð ·²ò Åïí ³³Ã ¼·¿³»¬»®
®±«²¼ -°»½·³»²ò
ìò ß ³·²·³«³ ±º º±«® øì÷ Ý¸¿®°§ Êó²±¬½¸ ·³°¿½¬ -°»½·³»²- ¿®» ¬± ¾» ®»³±ª»¼ º®±³ ¬¸» •ÝŒ -·¼» ±º Ï«¿¼®¿²¬ îò Ì¸» ²±¬½¸»¼ °±®¬·±² ±º
»¿½¸ -¿³°´» -¸±«´¼ ¾» ´±½¿¬»¼ »²¬·®»´§ ©·¬¸·² ¬¸» ¾«·´¼«° ®»¹·±² ±º ¬¸» ¬»-¬ ®±´´ ¿²¼ ±®·»²¬»¼ ¿- ·²¼·½¿¬»¼ ·² ¬¸» ¿¾±ª» -½¸»³¿¬·½ò Ì¸»
Ý¸¿®°§ Êó²±¬½¸ -°»½·³»²- -¸±«´¼ ½±²º±®³ ¬± ¬¸» ®»¯«·®»³»²¬- ±º ßÉÍ Þìòðò
Í±«®½»æ Ú·¹«®» -«°°´·»¼ ½±«®¬»-§ ¬¸» Ë²·¬»¼ Í¬¿¬»- Í¬»»´ Ý±®°±®¿¬·±²‰Ì»½¸²·½¿´ Ý»²¬»®å ¿¼¿°¬»¼ ¬± ¿¼¼ ³»¬®·½ ¼·³»²-·±²-ò
Figure 18Roll Buildup Qualification Tests

Qualification of BuildupLocation of Test Samples
Testing of Welds. Testing temperature should be speci- 19. If Level 2 or 3 qualification is required then the
fied by the Purchaser. buildup tension test sample are to be secured from the
roll/cylinder as shown in Figure 18. Testing is to be in
For Level 1 qualification of buildup materials, impact
accordance with AWS B4.0, Standard Methods for
test sample can be taken from weld metal using the test
Mechanical Testing of Welds. Acceptance criteria should
configuration shown in Figure 19. It should be assured
that the notch is placed in undiluted weld metal. For Level meet the Purchasers requirements or the roll manufac-
2 or 3 qualification of buildup material, refer to Figure turers specifications.
18. For all levels of qualification involving the overlay, 9.3.6 Thermal Fatigue. This test is intended to judge
test configuration shown in Figure 19 should be used. the suitability of the overlay material for a service envi-
9.3.5 Tension Tests. Generally, tension tests are rec- ronment that includes thermal shock. It is the responsibil-
ommended only for buildup and journal repair qualifica- ity of the buyer to specify the test parameters (test heating
tion. These types of tests usually are secured from and cooling rates, time at temperature, cooling method,
unlimited thickness all-weld-metal coupons taken from etc.) that represent the service environment. The locations
plate tests for Level 1 qualifications as shown in Figure of the test coupons are shown in Figure 16. It should be
30
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Ð®±ª·¼»¼ ¾§ ×ØÍ «²¼»® ´·½»²-» ©·¬¸ ßÉÍ
Ò± ®»°®±¼«½¬·±² ±® ²»¬©±®µ·²¹ °»®³·¬¬»¼ ©·¬¸±«¬ ´·½»²-» º®±³ ×ØÍ Ò±¬ º±® Î»-¿´»
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îò Ì¸» ¾¿½µ·²¹ ¬¸·½µ²»-- -¸±«´¼ ¾» ïñî ·²ò Åïí ³³Ã ³·²å ¾¿½µ·²¹ ©·¼¬¸ -¸±«´¼ ¾» í ·²ò Åéë ³³Ã ³·² ©¸»² ²±¬ ®»³±ª»¼ º±® ®¿¼·±¹®¿°¸§ô
±¬¸»®©·-» ï ·²ò Åîë ³³Ã ³·²ò
Figure 19Level 1 Tensile Test for Journal and Buildup Materials
recognized that there is no standardized test method to [595°C] and a second series of samples is tempered at
evaluate thermal fatigue performance of overlays. Gener- 1200°F [650°C] for the same length of time. Hardness
ally, this test is conducted to compare the performance of readings are taken after the samples cool to room temper-
new overlay materials against existing overlays. ature. The buyer should specify the test temperatures if
other temperatures are to be used. It is recommended that
9.3.7 Hot Hardness. This test is intended to judge the the tempering temperatures selected are representative of
ability of the overlay to maintain its strength, as mea- the roll service environment. The test sample locations
sured by hardness, at elevated temperatures. Typically a are shown in Figure 16.
sample is removed from the roll/cylinder and hardness
tested at room temperature 70°F [20°C]. Then the sample 9.3.9 Microstructure. This test is intended to reveal
is heated to test temperatures of 600°F [315°C], 800°F the microstructural detail of the overlay in the final con-
[425°C], 1000°F [535°C], 1100pF [595°C], and 1200°F dition supplied for an intended service. It is useful in
[650°C] and held at each of these temperatures for two detecting micro-cracks both in the overlay and heat-
hours. Hardness indentations are made while the sample affected-zone (HAZ). The contractor should select an
is at these test temperatures and either directly read or appropriate etchant to document the features of the
calculated after the sample has cooled to room tempera- microstructure as related to the intended service envi-
ture. Experience has shown that the above recommended ronment. The location of the test sample is shown in
test temperatures give a good indication of the hot hard- Figure 16.
ness of overlays. However users can select other temper-
9.3.10 Temper Embrittlement. This test is intended
atures for this test. The sample location is shown in
to measure the resistance of buildup materials to temper
Figure 16.
embrittlement. The test samples should be removed from
9.3.8 Temper Response. This test is intended to mea- the roll/cylinder coupon shown in Figures 17 and 18.
sure the overlays resistance to softening as a function of Various heat treatment schedules have been employed to
time and temperature. A series of test samples is evaluate temper embrittlement. The schedule should be
removed from the roll/cylinder. Samples are tempered in agreed upon by the Contractor and Purchaser. A sug-
a furnace for 5, 10, 20, 50, and 100 hours at 1100°F gested schedule, which lasts about 10 days, is as follows:
31
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1. Heat to 1100°F [593°C], hold 1 hour; should not be used to predict service life of the roll
overlay.
2. Furnace cool at 10°F [5.5°C] per hour to 1000°F
[538°C] and hold for 15 hours; 9.3.12 Wear. This test is intended to measure the resis-
tance of the overlay materials to wear. The test samples
3. Furnace cool at 10°F [5.5°C] per hour to 975°F should be removed from the roll/cylinder coupon. The buyer
[524°C] and hold for 24 hours; should determine the type of wear test based on knowledge
4. Furnace cool at 10°F [5.5°C] per hour to 925°F of the service environment. Tests can be wet or dry, room or
[496°C] and hold for 60 hours; elevated temperature, and low or high load. This test can
provide comparative data when a base-level reference can
5. Furnace cool at 10°F [5.5°C] per hour to 875°F be established. However this test should not be used to pre-
[468°C] and hold for 100 hours; dict service life of roll overlays. A number of wear tests may
be applied, including ASTM G 65, G 77, and G 83, but none
6. Furnace cool at 50°F [28°C] per hour to 600°F of these tests simulate the situation in industrial mill roll ser-
[315°C], then air cool to ambient. vice. Interpretation of test results should be mutually agreed
9.3.11 Corrosion. This test is intended to measure the between the Contractor and Purchaser.
resistance of the overlay material to corrosive attack. The 9.3.13 Composition Profile. This test is intended to
test samples should be removed from the roll/cylinder measure the variation in composition of the overlay
coupon as shown in Figure 16. The test should be con- when the roll working diameter is reduced from start size
ducted in accordance with ASTM G 48, Practice A6 or to scrap size. The buyer should specify the start and
other suitable test methods, except that the samples from scrap diameters and the number of composition test loca-
the roll surface are to contain at least two adjacent weld tions. The composition test sample should be removed
beads. This test can provide comparative data when a from the roll/cylinder coupon and machined to a configu-
base reference can be established. However the test ration as shown in Figure 20. This test is intended to
establish the effect of weld dilution and verify that roll
6 Tests have been conducted in accordance with ASTM G 48 working surface composition will conform to the buyers
Practice A. However, this test is rather severe and proper inter- specification as the roll diameter is reduced in service to
pretation of the results is difficult. scrap diameter.
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îò Ô±½¿¬·±²- ±º ¬¸» -«®º¿½»- ¬± ¾» ¿²¿´§¦»¼æ º·ª» ·²½®»³»²¬¿´ -¬»°- ±º ðòðëð ·²ò Åïòí ³³Ã ·²¬± ¬¸» -«®º¿½»ô -¬¿®¬·²¹ º®±³ ¿ ´±½¿¬·±² ±² ¬¸»
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Location of Chemical Analysis SamplesSample 1A1
32
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10. Repair and Correction and the Manufacturer should agree to the essential crite-
ria for the repair or correction of nonconformance.
10.1 General
10.3.2 It should be the obligation of the Manufacturer
10.1.1 This section covers the repairs and/or correc- to submit a detailed manufacturing process to the Pur-
tions of nonconformances found during inspections. chaser/user, which addresses the repair/correction of
Nonconformances include deviations of the dimensional nonconformance. The Manufacturer should address the
and surface finish requirements of the drawing, reject- following items.
able nondestructive examination indications, or addi-
tional requirements agreed to by the Purchaser and 1. Third party work;
Manufacturer which are not met. It covers repairs and/or
corrections to the base roll forging (journals or body), the 2. Repair options and types;
weld buildup of the roll body, the weld buildup of the 3. Acceptance and Rejection criteria;
roll journals, and the roll body overlay.
4. Purchaser and User notification and reporting;
10.1.2 The determination as to the disposition of non-
conformance should ultimately be at the discretion of the 5. System to address each nonconformance; and
Purchaser unless otherwise agreed upon between the
Purchaser and the Manufacturer. It is recommended that 6. The Purchaser may require a separate WPS for
acceptance/rejection criteria be established and agreed to repair welding to correct nonconformance.
by the Purchaser and the Manufacturer prior to the initia- 10.3.3 It should be the obligation of the Purchaser to
tion of work. provide the Manufacturer, when necessary, with the
10.1.3 Repair or correction work performed by those operating conditions of each roll type. This information
other than the Manufacturer should have approval from should provide the Manufacturer with as much informa-
the Manufacturer and should be performed in accordance tion as possible so that the Manufacturer can successfully
with the Manufacturers and Purchasers requirements. develop, submit, and implement a manufacturing process
which addresses the items in 10.3.2.
10.2 Examples of Nonconformance
10.2.1 Roll body and journal nonconformance may
include discontinuities, defects, and imperfections
caused by the welding, heat treatment, or machining 11. Finish Machining and Final
operations. Some examples are listed below: Inspection
1. Tool breakage during the final machining

11.1 Setup. If bearing journals or other critical areas of
operation;
the roll have not been welded and conform to drawing
2. Linear indications, trapped flux/slag, pitting, specification, the roll should be lined up to these areas to
porosity; prevent runout. The roll should be centered as necessary
to ensure that all critical surfaces will be concentric.
3. Nonuniform hardness and/or hardness measure-
ments not within the specified range; 11.2 Rough Machining. Normally, rough machining is
necessary to remove excess stock, relieve residual
4. Insufficient material to finish to required diameter;
stresses, and prepare the surface for inspection prior to
5. Handling damage; final machining. Stock allowed for final machining
should be kept to a minimum so that subsequent inspec-
6. Chemical analysis of the weld overlay not within
tions of the roll surface will be as close as possible to the
the specified range;
final dimension. Also, chemical analysis of the overlay
7. Incorrect heat treatment cycle; and close to the final size may be required. The stock allow-
ance is dependent upon the final machining methods, roll
8. Dimensional and surface finish deviations from material, and the drawing specifications. Weld fusion
drawing requirements. lines between welded and unwelded areas of the roll
10.3 Purchasers and Manufacturers Obligations should be undercut to remove stress risers.
10.3.1 Due to the diversity of rolls and their applica- 11.3 In-Process Inspection. One or more of the follow-
tions covered by this standard, it would be inappropriate, ing inspection methods should be performed to ensure
if not impossible, to cover all methods for repairing or that the roll will satisfy drawing specifications after final
correcting nonconformances. Therefore, the Purchaser machining.
33
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11.3.1 Visual Inspection. The roll should be visually 12. Quality Assurance
inspected for surface defects and noncleanup of the
welded surfaces. A qualified inspector (qualified to SNT 12.1 General. The Manufacturer should be responsible
TC-1A, QC1, or other equivalent programs as agreed to for the development of a system to ensure quality. This
by the Purchaser and Manufacturer) should conduct the system should be developed to encompass all roll types
inspection of the prepared surface. or be easily modified to suite particular roll applications.
The system should be developed by the Manufacturer
11.3.2 Dimensional Inspection. Dimensional inspec- and be capable of meeting both the requirements of this
tion should be performed to ensure all areas can be standard and the Purchasers quality control system. A
acceptable after final machining. Total indicated runout written description of the system should be submitted to
of all critical surfaces should be verified and the roll cen- the Purchaser in addition to the documentation refer-
tered as necessary to ensure concentricity at final enced by this standard and the Purchaser. All documen-
machining. tation including quality system documents should be
11.4 Final Machining. All welded surfaces should be mutually agreed to by the Manufacturer and the Pur-
machined to drawing specifications. Particular attention chaser prior to the initiation of work. It is recommended
should be given to high stress areas such as inside cor- that proprietary information be protected by a written
ners at shoulders and grooves. The radii in these areas agreement between the Manufacturer and the Purchaser.
should be to drawing dimensions and should be free of
12.2 Quality System Outline. Listed below are recom-
tool marks, which could cause stress risers and potential
mended guidelines for items which should be addressed
failure.
in the written description of the Manufacturers quality
11.5 Final Inspection. All inspection criteria and accep- control system.
tance standards should be mutually agreed to by Pur-
12.2.1 Authority and Responsibility. The authority
chaser and Manufacturer. One or more of the following
and responsibility of those in charge of the Manufac-

inspection methods should be performed to determine
turers quality control system should be clearly estab-
areas of nonconformance.
lished. Persons performing quality control functions
11.5.1 Visual Inspection. Visually inspect the roll for should have adequate training and authority to identify
obvious defects, stress risers, appearance and proper quality control issues, reject nonconforming product, and
identification. A qualified inspector (qualified to SNT implement immediate corrective actions required to
TC-1A, QC1, or other equivalent programs) should con- resolve nonconformance problems within the Manu-
duct the inspection of the prepared surface. facturers organization. An organizational chart illustrat-
ing the relationships between management, engineering,
11.5.2 Dimensional Inspection. The roll should be purchasing, manufacturing, inspection, quality, and qual-
inspected for conformance to dimensional tolerances. ity control, should be a requirement of the Purchaser
and be part of the Manufacturers quality control system
11.5.3 Nondestructive Examination. Nondestructive
documentation.
examinations should be performed per 5.5.3. In addition,
surface finish tests may be required. 12.2.2 Drawing and Specification Control. The
Manufacturers quality control system should provide
11.5.4 Chemical Analysis. Chemical analysis of the
procedures that ensure that the latest applicable draw-
overlay material may be required. Care should be taken
ings, specifications and procedures are consistently uti-
to insure that the sample analyzed is representative of the
lized for manufacturing, inspection, and testing.
working surface of the roll. This is of particular concern
with stainless steel overlays where the working surface 12.2.3 Material Control. The Manufacturer should
should be located within the top layer (refer to dark include a system of purchasing and receiving control that
bands in 8.4.8.4). ensures that the material received is properly identified
11.6 Nonconformance. Refer to Section 10 for informa- and that this identification remains with the product
tion on actions for nonconformance. throughout processing. Documentation, including all
material certifications and material test reports, should
11.7 Documentation and Reporting. The documenta- satisfy the requirements of the Purchasers quality sys-
tion and reporting of all inspections should be completed tem. In addition a system for material handling and stor-
as required by customers and QA agencies, internal and age should exist and should satisfy the requirements of
external. A typical form for reporting final inspection both this recommended practice and the Purchasers
results is shown in Figure C.1. quality system.
34
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12.2.4 Examination and Inspection. The Manu- 12.2.7 Heat Treatment. The quality control system
facturers quality control system should provide a written should provide controls to ensure that heat treatments,
description of the entire manufacturing process including when applicable, are implemented in accordance with
examination and inspection procedures. the requirements of this standard in addition to those of
the Purchaser.
12.2.5 Correction of Nonconformities. The Manu-
facturers quality control system should provide methods 12.2.8 Key Input and Output Process Variables/
for addressing the correction of nonconformities. The Characteristics. The quality control system should pro-
system should also provide a documented reporting vide a format to monitor, measure, and document key
format to the Purchaser which addresses not only meth- process variables. Process variables should meet the
ods for correction of nonconformities but corrective recommendations of this standard, be mutually agreed to
actions which should be implemented to prevent future by the Manufacturer and Purchaser, and fulfill the
nonconformities. requirements of the Purchasers quality system.
12.2.6 Nondestructive Examination. The quality 12.2.9 Documentation. The quality control system
control system should include provisions for identifying should supply the Purchaser pertinent, mutually agreed
the nondestructive examination procedures the Manufac- to information for each roll or batch of rolls on a timely
turer will implement to conform to the requirements of basis. The required information should be in accordance
this standard and the Purchasers requirements. with this standard and the requirements of the Purchaser.
35
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36
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This annex is not a part of AWS D14.7/D14.7M:2005, Recommended Practices for Surfacing
A1. Flux-to-Wire Relationship types of descriptions which can convey considerable

information about a flux and its potential for producing a
Submerged arc welding (SAW) has the possibility to sig- change from the wire composition to the deposit compo-
nificantly alter the composition of the weld deposit as sition. These descriptions are methods of manufacture
compared to that of the filler wire, depending upon the and metallurgical characteristics.
specific flux used and, to a certain extent, upon the ratio
of flux melted to wire melted. The flux to wire melt ratio
in turn depends largely upon voltage (arc length) and
wire feed speed and diameter, though electrode exten-
A3. Flux Types by Method of
sion, flux composition and density, travel speed, and arc Manufacture
polarity also play roles. If everything else is held con-
A3.1 Fused Fluxes. Some SAW fluxes are manufactured
stant, increasing voltage increases the arc length and
by melting the mineral components in a furnace into a
therefore increases the flux-to-wire ratio. On the other
homogeneous liquid. The molten flux is then discharged
hand, increasing wire feed speed (current) increases the
from the furnace and cooled. Cooling can be achieved
volume of metal reacting with a given volume of flux,
either by spraying the molten flux with a water stream, or
decreasing the flux-to-wire ratio. As the flux to wire ratio
by pouring it into a chill mold or through chill rolls. The
increases, the potential for changes from the wire com-
solidified flux is then crushed to desired size for handling
position to the deposit composition increases. Then the
and weldability. Such fluxes are termed fused fluxes. It
actual change which occurs depends upon the specific
is not possible for fused fluxes to contain metal compo-
flux used as well as upon the flux-to-wire ratio.
nents (Mn, Si, Cr), so that the possibility of composition
change, from the wire composition to the deposit compo-
sition, is somewhat limited, but not eliminated, with
A2. Flux Types fused fluxes. In particular, significant pickup of Mn
and/or Si can occur when a manganese silicate based flux
There is no AWS classification system for fluxes alone. is used with a high carbon or high chromium wire.
Mild steel and low alloy steel SAW wires and the fluxes
with which they are used are classified by AWS accord- A3.2 Bonded Fluxes. Other SAW fluxes are manu-
ing to the mechanical properties and deposit composition factured by mixing finely divided powdered minerals,
produced under standardized welding conditions by a and possibly powdered deoxidizers and/or alloy elements
specific flux/wire combination. That classification then as well, with a viscous liquid bonding agent, typically
conveys little or no information about performance of the water glass (silicates of sodium, potassium, and/or lith-
flux with another wire, especially a high carbon wire or a ium dissolved in water). By controlled mixing, pelletizing,
high chromium wire. So flux classification has little and sintering, flux particles are produced containing all
meaning in metalworking roll welding, except when of the constituent minerals, deoxidizers, and alloy
AWS provides for classification with the wire in use. elements, if added. The binder prevents the various
However, fluxes can be described to a certain extent powdered constituents from separating. Such fluxes
without AWS (or other) classification. There are two are termed bonded or agglomerated fluxes. When
37
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deoxidizers and/or alloy elements are added to the flux, A4. Flux Types by Metallurgical
the potential for composition changes from the wire to
the deposit is increased. However, not all bonded fluxes
Characteristics
contain metallic materials. A4.1 Basic Versus Acid Flux. From a metallurgical
point of view, a SAW flux used in metalworking roll
A3.3 Recycled Slag (Crushed Slag). Some welding
welding can be described as basic, acid, active, neutral,
shops will collect the SAW slag generated during weld- and/or alloy. A flux can be both basic and active, or both
ing and send it to a crushing operation (internal or exter- acid and active. Basicity or acidity are determined by the
nal) to be crushed to a size suitable for reuse as a welding various oxides present in the flux. Flux that contains a
flux. Since this slag has reacted with the welding wire large portion of silica is generally acid. Flux that con-
already, as well as having reacted with any scale or dirt tains little silica is generally basic. A Basicity Index
present during welding, the crushed slag will not be iden- (B.I.) was defined by the International Institute of Weld-
tical in composition and reaction potential with the origi- ing (IIW) as:
nal virgin flux. In particular, if the virgin flux contained
deoxidizers and/or alloy elements, these will have been CaO + MgO + BaO + SrO + Naa2O + K2O + Li2O + CaF2 + 0.5 MnO + 0.5 FeO
B. I. =
consumed (transferred to the weld pool) during the origi- SiO2 + 0.5 Al2O3 + 0.5 TiO2 + 0.5ZrO2
nal melting, so they are not available in the crushed slag,
which has become a new welding flux. If SAW slag is where the weight percent of each constituent is entered in
the formula above. A flux whose B.I. is less than 1.0 is
collected from more than one source, reactions with
termed acid. A flux whose B.I. is greater than 1.5 is
more than one wire could have taken place, which
termed basic. A flux whose B.I. is between 1.0 and 1.5
increases the possible variation in the new flux. If the
is termed neutral, although this latter term can lead to
practice of collecting SAW slag, crushing it, and reusing
some confusion because neutral is also used as a term
it as new SAW flux is adopted, it is recommended that a
for a flux which does not produce much change in
closed loop system be used, to provide for quality
deposit Mn and Si when large voltage changes occur as
assurance. This means that only slag obtained from using
noted in A4.2.
a particular wire in one shop be collected, kept free of
contaminants (including moisture), crushed, and used as Acid fluxes, when used with wires high in chromium and
new flux. carbon, tend to produce both carbon and chromium
reduction in the deposit as compared to the wire compo-
A3.4 Mechanically Mixed Fluxes. It is possible to sition, and the magnitude of the change depends upon
mechanically mix, or blend, two or more fluxes to make flux-to-wire ratio. On the other hand, basic fluxes pro-
a new, different flux. Mechanically mixed fluxes can duce very little change in deposit carbon and chromium
have a tendency to separate again because of density dif- content as compared to the wire composition, and there
ferences among the various flux particles blended into is little effect of large changes in flux-to-wire ratio.
the new flux, so they should be handled carefully to
avoid vibrations, which promote separation. Crushed A4.2 Active Versus Neutral Fluxes. Active fluxes con-
slag alone generally does not have welding characteris- tain enough metallic Mn and/or Si so that rather large
tics (bead shape, wetting) that are as good as those of the changes in deposit Mn and/or Si content occur with large
virgin flux. Therefore, when crushed slag, as described changes in flux-to-wire ratio. A Wall Neutrality Num-
in A3.3, is supplied as a new SAW flux, it is common to ber (N) has been defined as:
blend the crushed slag with virgin flux in a specific pro-
N = 100 (| %Si| + | %Mn|)
portion so that this mechanical mixture is considered to
be the new flux. In any case, the original manufacturer of where | % Si| is the absolute value of the change in all-
the virgin flux cannot be considered the manufacturer of weld-metal silicon content, and | % Mn| is the absolute
the crushed slag or of a blend of crushed slag with virgin value of the change in all-weld-metal manganese
flux because the product has been altered beyond the content, obtained at 36 volts as compared to welding at
original manufacturers control. In a closed loop system 28 volts, all other conditions maintained constant. If N is
using crushed slag, the welding shop may be considered greater than 40, the flux is said to be active. If N is 40
the flux manufacturer. In an open loop system using or less, the flux is said to be neutral. However, because
crushed slag, the slag crusher (blender) may be consid- of possible confusion with neutral as a term applied to
ered the flux manufacturer. In either a closed loop sys- a flux with B.I. of 1.0 to 1.5, the term nonactive will be
tem or an open loop system of slag crushing and reuse as used instead when N not greater than 40 is meant in the
SAW flux, the user of the flux should verify the quality remaining discussion. An increase in Mn or Si may pro-
assurance system covering the new flux. duce a significant increase in deposit hardness, particu-
38
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larly when the deposit is mild steel buttering or low alloy the flux supply system. This flux is normally heated by
steel buildup. its proximity to molten slag during welding, which helps
to keep it dry. However, a mechanically mixed flux, such
A4.3 Alloy Fluxes. An alloy flux is a flux, which con-
as a blend of crushed slag and virgin flux, may separate
tains metallic alloy elements within the flux particles.
in the vacuum collection and delivery system. In this
These alloy elements are melted and mixed with the weld
case, it is advisable to separate vacuum collection from
pool to add alloy elements to the deposit. For metalwork-
delivery back to the welding head, and provide a
ing roll welding, alloy fluxes are generally used with car-
reblending step between collection and delivery. Also,
bon steel wires, typically AWS A5.17, Specification for
repeated cycles of vacuum collection and delivery back
Carbon Steel Electrodes and Fluxes for Submerged Arc
to the welding head may result in some breakdown of
Welding, Class EL12, to produce low alloy steel buildup
bonded flux particles, especially those containing metal-
or 12% Cr stainless steel overlay. Since all of the deposit
lic deoxidizers and/or alloy elements. Then, some separa-
alloy content comes from the flux, consistent deposit
tion of high density metallic particles from lower density
composition and properties in this situation are critically
mineral particles can occur, and weld deposit homogene-
dependent upon maintaining constant flux-to-wire ratio.
ity may be adversely affected. The supplier of an active
Rigid control of voltage, wire feed speed, stickout, and
or alloy flux should be contacted for guidance on the
other welding variables is essential to obtain uniform
number of repeated cycles of vacuum collection and
deposits.
delivery back to the welding head which are advisable
for a particular flux.
A5. Flux Storage and Handling

Flux should be protected from contamination before use. A6. Welding Wires for Metalworking
The most common and often most important contami- Roll Welding
nant is moisture. All fluxes have some tendency for
moisture pickup when exposed to humid air. Fluxes are Welding wires for metalworking roll welding are gener-
most commonly packaged by their manufacturer in ally provided in large drums containing as much as
multi-layer bags which afford considerable protection 500 or 750 lb [225 or 340 kg]. Common sizes used are
from atmospheric moisture. In undamaged bags and pro- 3/32 in. [2.5 mm], 1/8 in. [3.2 mm], and 5/32 in. [4 mm].
tected from contact with liquid water, flux can usually be 1/16 in. [1.6 mm] wire might be used on rolls of about
stored for six months minimum without adverse effects 6 in. [150 mm] diameter or less. And 3/16 in. [4.8 mm]
during welding. Sealed plastic bags or sealed pails pro- wire might be used on large rolls. The drums provide
vide even better protection. Once the original package protection of the wire from rusting for at least six months
has been opened, storage in a heated oven at about 210°F if the drums are maintained in a dry location. Rusting of
[100°C] is commonly recommended. the wire is the factor which usually limits its storage life.
Rusted wire can cause feeding difficulties, as well as
Flux which has been exposed to atmospheric humidity introducing oxygen and moisture into the weld pool.
can be returned to fully dry condition by rebaking. Typi-
cal rebake temperatures depend upon the specific flux Metalworking roll welding systems use many variants of
in question. For fused fluxes, rebaking at 300 to 500°F single wire SAW. Multiple welding heads may be used
[150 to 260°C] is commonly recommended. For bonded in various locations along a rolls length. This approach
fluxes, 500 to 700°F [260 to 370°C] is commonly recom- requires careful attention to tie-in between the deposit of
mended. The manufacturer of the flux should be con- one head and that of the next head along the rolls length,
tacted for more specific flux rebaking recommendations. but it increases overall deposition rate to allow comple-
It should be noted that SAW flux is a rather good insula- tion of the roll welding in less time. It also helps to main-
tor, so that effective rebaking requires either burying a tain the roll mass at or above minimum preheat and
thermocouple in the center of the flux depth and monitor- interpass temperatures, though it requires care to not
ing at least one hour at rebake temperature at the mid- overheat the roll. Twin wires, typically 3/32 in. [2.5 mm],
depth of the flux, or holding the flux at the rebake tem- fed into a single weld pool can offer higher deposition
perature for at least one hour per 1 in. [25 mm] of maxi- rate from a single head.
mum flux depth in the oven. When flux is being rebaked,
Wires for SAW of metalworking rolls may be solid or
it is important that the oven contain no other sources of
tubular metal cored. Wires for buttering (applying a layer
moisture.
of mild steel) over the roll body or bearing journal area
During welding, unmelted flux particles are commonly are commonly solid mild steel wires classified to AWS
picked up by a vacuum collection system and returned to A5.17, Specification for Carbon Steel Electrodes and
39
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Fluxes for Submerged Arc Welding, as EL12, EM12K, or eventually result in clogging. Tubular wires are generally
EH14. Typically, the EL12 wire would be used for but- mechanically softer, and excessive drive roll pressure,
tering with an active flux; the EM12K wire would be especially when the drive roll shape is not contoured to
used with an acid flux or a nonactive basic flux; and the the wire shape, may distort the wire and cause feeding
EH14 wire would be used with an acid nonactive flux. In difficulties. Distortion of tubular wire may also cause the
all three buttering examples, the objective is to produce a mechanical seam which closes the tube to open partially,
low carbon deposit of low hardenability (typically with resulting in leakage of core material. Leakage may in
Mn less than 1.6% and Si less than 0.8%) which can act turn clog the wire feeding mechanism or the contact tip.
as a barrier to crack nucleation and propagation. So, generally more attention to feed roll design and pres-
sure is necessary for trouble-free feeding of tubular
The same solid mild steel wires, especially the EL12
wires. With very soft tubular wires, U-grooved cog drive
class, may be used with an alloy flux to produce a low
rolls may be necessary for proper wire feeding. The man-
alloy steel buildup layer, or, with another alloy flux, to
ufacturer of the tubular wire should be contacted for
produce a 12% Cr stainless steel overlay. Some of these
drive roll recommendations.
alloy fluxes are recommended for use in DCEN welding
to maximize flux (alloy) melting and minimize both wire Solid wires are often sold on the basis of the wire compo-
melting and penetration. The flux manufacturers recom- sition, without regard to the weld deposit composition.
mendations should be consulted and carefully adhered to This is a very acceptable practice in classifying mild
for such applications. A change in flux-to-wire ratio will steel wires. However, in the cases of depositing low alloy
change the deposit composition and therefore the deposit steel buildup, tool steel, or 12% Cr stainless steel over-
properties. lay, reaction of a specific flux with chromium and carbon
Some low alloy steel wires, some tool steel wires, and in the wire should be considered. As noted previously,
some 12% Cr stainless steel wires, are available in solid acid fluxes tend to significantly reduce the carbon and
form for depositing low alloy steel buildup layers, tool chromium content of the weld deposit as compared to
steel overlay, or 12% Cr stainless steel overlay, respec- that of the wire. Since the weld deposits carbon and
tively, with unalloyed flux. However, rather limited com- chromium content respectively and largely determine the
positions are available, due to the need for the wire to deposit hardness and corrosion resistance, it is appropri-
be produced as a heat of steel, typically 120 000 lbs ate to consider the deposit composition with a particular
[55 000 kg] or more. To provide more flexibility for the flux even when using solid wire.
metalworking roll welding shop, most of the wires for
Tubular wires for depositing low alloy steel buildup, tool
depositing low alloy steel buildup, tool steel or 12% Cr
steel, or 12% Cr stainless steel overlay are generally
stainless steel overlay with unalloyed fluxes today are
tailored to a specific flux to produce a desired all-weld-
produced as tubular metal cored wires. These tubular
metal composition. Use of a wire designed for an acid
wires are manufactured from a mild steel sheath and
flux with a basic flux is likely to produce appreciably
filled with the required alloy elements. Then much
higher carbon and chromium levels in weld deposits than
smaller production runs of a given wire can be manufac-
it would with the designed acid flux. Conversely, use of a
tured, and specialized compositions are readily produced.
wire designed for a basic flux with an acid flux is likely
Solid wires offer the advantage of being mechanically to produce appreciably lower deposit carbon and chro-
hard, so that rather large variations in wire feeding drive mium than it would with the designed basic flux. In
roll design and drive roll pressure can be acceptable, either mismatch case, deposit properties may be inappro-
though excessive pressure may cause spalling of copper priate to the desired end. Careful evaluation of such a
flashing which then collects in contact tips and may mismatch should be made before putting it into service.
40
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º±® ßÉÍ Ì»½¸²·½¿´ Ý±³³·¬¬»»-

B1. Introduction along with the edition of the standard that contains the
provisions or that the inquirer is addressing.
The AWS Board of Directors has adopted a policy
whereby all official interpretations of AWS standards B2.2 Purpose of the Inquiry. The purpose of the inquiry
will be handled in a formal manner. Under that policy, all must be stated in this portion of the inquiry. The purpose
interpretations are made by the committee that is respon- can be either to obtain an interpretation of a standards
sible for the standard. Official communication concern- requirement, or to request the revision of a particular
ing an interpretation is through the AWS staff member provision in the standard.
who works with that committee. The policy requires that B2.3 Content of the Inquiry. The inquiry should be
all requests for an interpretation be submitted in writing. concise, yet complete, to enable the committee to quickly
Such requests will be handled as expeditiously as possi- and fully understand the point of the inquiry. Sketches
ble but due to the complexity of the work and the proce- should be used when appropriate and all paragraphs, fig-
dures that must be followed, some interpretations may ures, and tables (or the Annex), which bear on the
require considerable time. inquiry must be cited. If the point of the inquiry is to
obtain a revision of the standard, the inquiry must pro-
vide technical justification for that revision.
B2. Procedure B2.4 Proposed Reply. The inquirer should, as a pro-
All inquiries must be directed to: posed reply, state an interpretation of the provision that
is the point of the inquiry, or the wording for a proposed
Managing Director, Technical Services revision, if that is what inquirer seeks.
American Welding Society
550 N.W. LeJeune Road
Miami, FL 33126 B3. Interpretation of Provisions of
All inquiries must contain the name, address, and affilia- the Standard
tion of the inquirer, and they must provide enough infor-
Interpretations of provisions of the standard are made by
mation for the committee to fully understand the point of
the relevant AWS Technical Committee. The secretary
concern in the inquiry. Where that point is not clearly
of the committee refers all inquiries to the chairman of
defined, the inquiry will be returned for clarification. For
the particular subcommittee that has jurisdiction over the
efficient handling, all inquiries should be typewritten and
portion of the standard addressed by the inquiry. The
should also be in the format used here.
subcommittee reviews the inquiry and the proposed reply
B2.1 Scope. Each inquiry must address one single pro- to determine what the response to the inquiry should be.
vision of the standard, unless the point of the inquiry Following the subcommittees development of the
involves two or more interrelated provisions. That pro- response, the inquiry and the response are presented to
vision must be identified in the scope of the inquiry, the entire committee for review and approval. Upon
41
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approval by the committee, the interpretation will be an only through a written request. The Headquarters staff
official interpretation of the Society, and the secretary cannot provide consulting services. The staff can, how-
will transmit the response to the inquirer and to the Weld- ever, refer a caller to any of those consultants whose
ing Journal for publication. names are on file at AWS Headquarters.
B4. Publication of Interpretations B6. The AWS Technical Committee

All official interpretations will appear in the Welding
The activities of AWS Technical Committees in regard
Journal.
to interpretations are limited strictly to the interpretation
of provisions of standards prepared by the committee or
to consideration of revisions to existing provisions on the
B5. Telephone Inquiries basis of new data or technology. Neither the committee
Telephone inquiries to AWS Headquarters concerning nor the staff is in a position to offer interpretive or con-
AWS standards should be limited to questions of a gen- sulting services on: (1) specific engineering problems; or
eral nature or to matters directly related to the use of the (2) requirements of standards applied to fabrications out-
standard. The Board of Directors policy requires that all side the scope of the document or points not specifically
AWS staff members respond to a telephone request for covered by the standard. In such cases, the inquirer
an official interpretation of any AWS standard with the should seek assistance from a competent engineer expe-
information that such an interpretation can be obtained rienced in the particular field of interest.
42
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ß²²»¨ Ý ø×²º±®³¿¬·ª»÷
Î»½±³³»²¼»¼ Ú±®³-
This annex contains five sample forms.
43
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Figure C.1Sample Form for Incoming and Final Inspection Records
44
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45
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48
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ANSI Z49.1, Safety in Welding, Cutting, and Allied Benedyk, J. C., D. J. Moracz, and J. F. Molloce, Thermal
Processes. Fatigue Behavior of Die Materials for Aluminum Die
Casting, Trans. 6th SDCE International Die Congress,
ASTM G 65, Standard Test Method for Measuring Abra- Cleveland, Ohio, Nov. 1619, 1970.
sion Using the Dry Sand/Rubber Wheel Apparatus.
Farmer, Howard, Steel Mill Roll Reclamation, Stoody
ASTM G 77, Standard Test Method for Ranking Resis- Technical Report, Second Edition, 1975.
tance of Materials to Sliding Wear Using Block-on-
Ring Wear Test. Handerhan, K., The Importance of Fracture Mechanics
in the Design of Forged Continuous Caster Rolls,
ASTM G 83, Standard Test Method for Wear Testing Table IV, Proceedings from the 1989 Mechanical
with a Crossed-Cylinder Apparatus. Working and Steel Processing Conference.
51
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Designation Title
D14.1/D14.1M Specification for Welding of Industrial and Mill Cranes and Other Material Handling Equipment
D14.3/D14.3M Specification for Welding Earthmoving, Construction, and Agricultural Equipment
D14.4/D14.4M Specification for Welded Joints in Machinery and Equipment
D14.5 Specification for Welding of Presses and Press Components
D14.6/D14.6M Specification for Welding of Rotating Elements of Equipment
D14.7/D14.7M Recommended Practices for Surfacing and Reconditioning of Industrial Mill Rolls
53
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54
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Under the Direction of the

550 N.W. LeJeune Road, Miami, FL 33126

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International Standard Book Number: 0-87171-028-5

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AWS D14H Subcommittee on Surfacing of Industrial Rolls and Equipment

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Ý±°§®·¹¸¬ ß³»®·½¿² É»´¼·²¹ Í±½·»¬§

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1. Scope Welding symbols shown on drawings should be compat-

Figure 1Typical Roll Types and Nomenclature

Figure 2View of Typical Roll Cross Section

Grade C Mn Si Ni Cr Mo V ksi MPa ft-lb J

end user and Manufacturer. Consideration should be

5.2.2 Parameters. The stress relief temperature is

expose employees and the environment to potentially used.

tive examination of all roll surfaces is recommended.

BU1 BU2 BU3 SS1 SS2 SS3 SS4 TS1 TS2

The composition of the overlay determines its as-welded

For rolls that are subjected to repeated heating and cool-

Figure 3Preheat Temperature as a Function of Carbon and Alloy Content

Í±«®½»æ ß¼¿°¬»¼ º®±³ Ú¿®³»®ô Ø±©¿®¼ô Í¬»»´ Ó·´´ Î±´´ Î»½´¿³¿¬·±²ô

Figure 4Required Soak Time at Temperature to Heat the Roll

Figure 5Preheat Temperature Effect on Roll Diameter Expansion

Ý±°§®·¹¸¬ ß³»®·½¿² É»´¼·²¹ Í±½·»¬§

Current, Amperes 350 to 500 400 to 550 450 to 600

Contact-Tip-to-Work 1 to1-1/4 in. 1-1/4 to 1-1/2 in. 1-1/4 to 1-1/2 in.

Deposition Rate 14 to 22 lb/h 16 to 24 lb/h 17 to 25 lb/h

Í±«®½»æ Ú·¹«®» -«°°´·»¼ ½±«®¬»-§ ±º Ì¸» Ô·²½±´² Û´»½¬®·½ Ý±³°¿²§ò

Figure 11Effect of Lead Position on Bead Solidification Lines

% Dilution Layer 1 Layer 2 Layer 3 Layer 4 Layer5 Layer 6

20% 10.40 12.48 12.90 12.98 13.00 13.00

30% 9.10 11.83 12.65 12.89 12.97 12.99

Figure 12Stepover Techniques

Ý±°§®·¹¸¬ ß³»®·½¿² É»´¼·²¹ Í±½·»¬§

9.2.1.2 Level 2 and 3 Qualifications. Level 2 and

9.3.1 Chemical Composition Analysis. A chemical

SAW FCAW GMAW

SAW FCAW GMAW

Filler Metal Variables (Contd)

Ý±°§®·¹¸¬ ß³»®·½¿² É»´¼·²¹ Í±½·»¬§

SAW FCAW GMAW

(2) Bead Technique X X X

toughness is a requirement, these variables are the same as those in Note a.

the WPS should be revised.

Figure 13Basic Bead on Plate Sample for Level 1 Qualification

Figure 14Roll Cylinder Sample for Level 1, 2, or 3 Qualification

Figure 15Roll Qualification TestsQualification of Hardfacing

Figure 16Roll Qualification TestsQualification of Hardfacing

Figure 17Roll Buildup Qualification Tests

Figure 18Roll Buildup Qualification Tests

Figure 19Level 1 Tensile Test for Journal and Buildup Materials

Figure 1Typical Roll Types and Nomenclature

Figure 2View of Typical Roll Cross Section

Figure 3Preheat Temperature as a Function of Carbon and Alloy Content

Figure 4Required Soak Time at Temperature to Heat the Roll

Figure 5Preheat Temperature Effect on Roll Diameter Expansion

Figure 11Effect of Lead Position on Bead Solidification Lines

Figure 12Stepover Techniques

Filler Metal Variables (Contd)

Figure 13Basic Bead on Plate Sample for Level 1 Qualification

Figure 14Roll Cylinder Sample for Level 1, 2, or 3 Qualification

Figure 15Roll Qualification TestsQualification of Hardfacing

Figure 16Roll Qualification TestsQualification of Hardfacing

Figure 17Roll Buildup Qualification Tests

Figure 18Roll Buildup Qualification Tests

Figure 19Level 1 Tensile Test for Journal and Buildup Materials

Figure 20Roll Qualification TestsQualification of Hardfacing

Figure C.1Sample Form for Incoming and Final Inspection Records

Figure C.2Sample Form for Welding Procedure Specification

Figure C.3Sample Form for Procedure Qualification Record

Figure C.5Sample Form for Recording Weld Processing Parameters

Figure C.5 (Continued)Sample Form for Recording Weld Processing Parameters