Overview Sarclad Limited Rolltex EDT range Rolltex EDC a new development project to replace chrome plating of textured rolls
Sarclad Limited Sarclad Ltd Headquarters, Sheffield UK Design & Manufacturing Product development Sales & marketing Service & after sales support Sarclad NA, Pittsburgh USA Sales & marketing Commissioning & service After Sales support Sarclad China, Shanghai Sarclad India, Bangalore Opened 2015
Sarclad Limited Providing Technology Based Equipment to The Metals Industry since 1977 Rolltex EDT for Roll Texturing > 90 units supplied worldwide
Rolltex EDT
The EDT Process Principle of EDT process Single spark created 20,000 times per second Electrode Plasma Gas Bubble Spark Roll surface Spark created between electrode and roll Gas bubble forms Spark melts roll surface forming a crater Gas bubble grows
The EDT Process Principle of EDT process Single crater
The EDT Process Principle of EDT process Multiple craters
What is EDT used for? EDT produces rolls with an homogenous texture.
Textured What is EDT used for? EDT rolls are used cold rolling applications to transfer the texture onto the sheet steel. 5 Stand Tandem 1 2 3 4 5 Batch Anneal Temper 56 inch (1424mm) Auto body Strip White Product Electro Zinc EDT & Chrome Plating Chrome Plated 1,2,3,4 Temper 80 inch (2000mm) Textured & Chrome Plated Hot Dip Galvanising Textured & Chrome Plated Skin Pass
What is EDT used for? EDT rolls used in Production of strip for Auto body and domestic white goods
EDT benefits EDT in Production of strip for Auto body and domestic white goods Surface Preparation for Coating Removes minor imperfections Better surface for bonding of paint coatings Industry standard for Automotive applications Formability Retains lubricant before and during pressing Reduces friction in the press Retains surface appearance after forming
Sarclad Rolltex EDT machine range Type 1-72 Electrodes for production of up to 1000 rolls per month Type 2-36 Electrodes for production of up to 600 rolls per month Type 3-12 Electrode for production of 300 rolls per month (or narrow strip, Z mills) Type 4 - Eco EDT low volume production up to 100 rolls per month
Sarclad Rolltex EDT machine range 72 Electrodes
Sarclad Rolltex EDT machine range 36 Electrodes
Sarclad Rolltex EDT machine range 12 Electrodes
Rolltex ECO
Sarclad Rolltex MICRO
Sarclad Rolltex - Main Components Electrodes
Sarclad Rolltex EDT machine main components Texturing head
Sarclad Rolltex EDT machine process simulation ROLL
Rolltex EDC
Electrical Discharge Coating (EDC) Collaborative project involving Sarclad, Tata NL and CRM EU-funded project CrFreeRolls Objective to find alternative for Cr-VI plating of temper mill work rolls
Electrical Discharge Coating (EDC) Principle V EDC electrode time Dielectric Power supply EDC layer Roll Texturing and surface hardening in one process
Recast layer thickness (µm) EDC Research 9 8 7 6 5 4 3 2 1 0 4 8 17 Pulse current (A) 8 passes 16 passes Significant influence of the applied current on the layer thickness
Recast layer deposited W
Recast layer deposited carbides Isolated WC deposits
Recast layer deposited carbides
EDC process optimisation Earlier trial Increased carbide deposition
Proportion (wt%) EDC Research 60 50 40 30 20 10 0 0 4 8 12 16 20 24 28 32 Number of passes Austentite 4A Austenite 8A Austenite 17A Cementite 4A Cementite 8A Cementite 17A Austenite and cementite content changes with number of passes at 4A
EDC Validation 2 pairs of Tata standard work rolls textured with EDC Texturing time around twice as long as EDT EDC of rolls at Sarclad for industrial trials at Tata Steel NL
Sarclad validation 3D topology of rolls 1 2 3 0 4 5 62 0-360 36-720 0 720 Drive side Sa: 2.44 Sa: 2.45 Sa: 2.46 Very homogeneous EDC surface finish across the roll
EDC Validation Tata NL temper mill 21 EDC rolls ready for industrial trials
Ra Ra (μm) (μm) EDC Validation Industrial trials roughness retention 2,5 Roughness on on coils coils (114K) - EDC comparison compared EDC with to Cr-pl EDT+Cr rolls 2 1,5 1 0,5 Campaigns rolled with Cr plated rolls EDC Ra constant during full-length 900 tons campaign Good strip surface quality 0 0 100 200 300 400 500 600 700 800 900 1000 cum weight (tons) Promising results prompting further industrial trials
EDC Summary Electrode manufacture optimised Isotropic EDC coated surface produced with hard constituents Thickness of recast layer can be controlled Laboratory tests roughness retention of EDC coating comparable to EDT + Cr-plating First industrial trials very promising Cost savings due to the elimination of additional hardening processes
EDC Future Commercialisation of EDC Product launch as part of Sarclad Rolltex equipment on all new EDT machines Upgrade available for all existing Sarclad machines
Experience + Innovation Over 35 years of experience Developing new solutions for new roll applications