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Casting & Forging Marketing

555, Guygok-dong, Changwon-City, Kyongsangnam-do 641-792, Korea


TEL: (82) 55-278-4757 Fax: (82) 55-278-8504
Internet Homepage
http://www.doosanheavy.com

Overseas Branches
Doosan Heavy Industries America Corp.
140 Sylvan Avenue, Suite 3B, Englewood Cliffs, NJ 07632, USA
DOOSAN
Phone: 1-201-944-4554 Fax: 1-201-944-5022/ 5053

Doosan Heavy Industries Japan Corp.


Room 307, Mita Kokusai Bldg. 1-4-28, Mita Minato-ku, Tokyo, Japan
Phone: 81-3-3452-5451~3 Fax: 81-3-3452-5624

Doosan Malaysia Sdn. Bhd. (Kuala Lumpur Office)


Letter Box No. 86, 22nd Floor, UBN Tower,
FORGED STEEL ROLLS O
10 Jalan P. Ramlee, 50250 Kuala Lumpur, Malaysia
Phone: 60-3-2026-8890 Fax: 60-3-2026-8891

Inkor Engineering Private Ltd.


1508, Maker Chambers 5, Nariman Point, Mumbai 400-021, India
Phone: 91-22-202-6504/ 2053/ 7842 Fax: 91-22-202-6557

Beijing Office
Room 1904, Landmark Bldg., 8 North Dongsanhuan Road,
Chaoyang Dist., Beijing 100004, China
DOOSAN HEAVY INDUSTRIES & CONSTRUCTION CO., LTD.
Phone: 86-10-6590-0924/ 0109 Fax: 86-10-6590-0991

Dubai Office
Office #1002, Al Moosa Tower II, Sheikh Zayed Road,
P.O.Box 11859, Dubai, UAE
Phone: 971-4-332-2703 Fax: 971-4-332-2714

Frankfurt Office
4th Floor, Arabella Center, Lyoner Strasse, 44-48,
60528, Frankfurt am Main, Germany
Phone: 49-69-69-5004 0 Fax: 49-69-69-5004 10

Riyadh Office
P.O. Box 9656, Riyadh 11423, Saudi Arabia
Phone: 966-1-419-1920/ 1696/ 0397 Fax: 966-1-419-1995

Taipei Office
704, No. 51, Keelung Road Sec. 2, Taipei, Taiwan, Republic of China
Phone: 886-2-2739-2255 Fax: 886-2-2739-2266

Schenectady Office
Room 33-202A, General Electric Bldg., 1 River Road, Schenectady, NY 12345, USA
Phone: 1-518-385-5218/ 2629 Fax: 1-518-385-4984

Windsor Office
2000 Day Hill Road, P.O. Box 500, Windsor, CT 06095, USA
Phone: 1-860-731-6482/ 6479 Fax: 1-860-731-6478
History in Brief
62 1962 : Established

93 1993 : Acquired ISO 9001 Certificate for Power Plant


and Industrial Plants
77 1977 : Started Power Plant Business

82 1982 : Completion of Plant 97 1997 : Started Forged Work Roll Business

84 1984 : Started Forged


Back Up Roll Business 00 2000 : Privatized to Doosan Group

Introduction 3
The Types of Forged Rolls 5
Manufacturing Sequence of Work Roll 7

Contents Manufacturing Sequence of Back Up Roll


Main Production Facilities for Forged Steel Rolls
11
14
Quality Assurance 15
Research & Development 17

Doosan Changwon Plant


(Total area: 4,425,570m2, floor space: 554,988m2) is composed of fifteen separate shops:
nuclear component fabrication shop, turbine and generator shop, steel making foundry
shop, roll shop, etc., and dock facilities.
Introduction
Doosan Heavy Industries & Construction Co., Ltd. (Doosan) has been producing various types
of casting & forging products for the many years ranging power generator, chemical
vessel, steel mill, ship building, and steel plant.

Doosan came into existence in 1962 as a pioneer in the field of heavy industries in korea.
since that time, it has manufactured and supplied various types of steel castings
and forgings both for domestics and foreign markets.

Forged Steel Rolls


A longer lasting roll means less down time for roll exchange and more production
tonnage of the mill which can make roll users save more dollars, milling costs.

Doosan’s forged work roll has a good combination, the hardened surface with high
resistance to wear, heat check and tough core resistance to breakage.
It also has an ideal hardness profile from surface to core and
very high resistance to spalling.

Doosan has three shops related to roll business, a steel foundry, a forge shop and a roll shop at its
Changwon manufacturing complex, all of which are equipped with the most
up-to-date facilities and equipments fully controlled automatically.
With the modern facilities, a strict quality system and the latest technical
know-how, we look forward to supplying our customers with the top quality rolls.

This catalogue presents the principal characteristics of each process together with brief
guidance on doosan’s forged rolls.
The Types of Forged Rolls
Work Rolls & Intermediate Rolls for Cold Rolling Mill

DOOSAN FORGED STEEL ROLLS


Small Sized Work Rolls for Cold Rolling Mill

Back Up Rolls for Cold, Hot and Plate Polling Mill


Chemical
Analysis

Q-steel Scrap & Ferro Alloys Melting & Refining Vacuum Refining Ingot or Electrode Casting Electrode Annealing Electro-Slag Remelting Heating Forging Special Annealing Rough Machining

(Conventional Type)
UST

HS HS

Shipment Packing Inspection (HS, UST, DI) Final Machining Tempering Sub-zero (N2 gas) Quenching Intermediate Machining Thermal Refining
and Final Grinding (Induction Hardening)

Manufacturing Sequence
of Work Roll
8

DOOSAN FORGED STEEL ROLLS


Work Roll & Intermediate Roll Hardening Depth of Work Rolls
Doosan Roll
Symbols Material Applications and Characteristics

Basic Work and Intermediate Rolls


R53HJ 3%Cr for Cold Rolling Mill

Deep Hardened Work


HR60 Modified 3%Cr and Intermediate Rolls

Work and Intermediate Rolls


KR21HJ 5%Cr With Improved Wear Resistances

Super Deep Hardened Work


HSR1 Modified 5%Cr
and Intermediate Rolls

Super Deep (100mm )


KR4HJ Modified 5%Cr Hardened Work
and Intermediate Rolls

Intermediate Rolls for


DSR1 Semi-HSS
Cold Rolling Mill
CHARACTERISTICS OF DOOSAN ESR PROCESS
Improvement of cleanliness in the
solidified ESR ingot by refining
porcess through the slag-metal
reaction

Minimization of segregation and


a crystal formation of fine
structure by the solidification
1. ESR lngot speed control
2
1 2. Forging

4 3. Low Frequency Induction

3 4. CNC Lathe
5
5. Automatic Ultrasonic Test

Manufacturing Sequence
of Work Roll

10

DOOSAN FORGED STEEL ROLLS


CHARACTERISTICS OF DOOSAN INDUCTION PROCESS
Induction heating coil gives a stable heating
Automatic temperature measuring system
keeps an accurate temperature control
Cooling shower supply a quick
and uniform cooling
Cooling water controlling system gives
a stable cooling
Hardening mechanism with high mechanical
precise provides a high quality hardness
deviation
Q-steel Scrap & Melting & Refining Vacuum Refining Ingot Making Forging (10,000 ton press) Preliminary Heat Treatment Rough Machining
Ferro Alloys (100 & 30t EAF) (ASEA-SKF L/D F’CE) (Vacuum Stream Degasser)

Hardening

Inspection Finishing M/C & Grinding Tempering Differential Quenching Differential Heating (80T) Preheating
Machine (80T)

Manufacturing Sequence
of Back Up Roll
12

DOOSAN FORGED STEEL ROLLS


Back Up Roll Hardening Depth of Back Up Roll
Doosan Roll
Symbols Material Applications and Characteristics

KFB43 3%Cr Basic Steel for Hot Strip Mill

High Hardness Steel for


KFB48 Modified 3%Cr Hot & Cold Strip Mill

High Hardness Steel for


KFB53 High C + 3%Cr Cold Strip Mill

Improved Wear Resistance for


KFB72 High C Plate Mill

Improved Wear Resistance for


KFB90 High C
Hot Strip Mill

Improved Wear Resistance and


HFB55 5%Cr High Toughness for Hot &
Cold Strip Mill
Manufacturing Sequence of Back Up Roll
MAIN PRODUCTION FACILITIES FOR
FORGED STEEL ROLLS

Shop Facilities Capacity


Electric Arc Furnace 100T 1 Unit
Steel
Electric Arc Furnace 30T 1 Unit
Foundry Shop
Vacuum Ladle Furnace 155T 1 Unit
Electro-Slag 80T 1 Unit
Remelting Furnace
Forging Press with 10,000T 1 Unit
Manipulator 4,200T 1 Unit
Forge Shop 1,600T 1 Unit
Heating Furnace 15~450T 13 Units
Heat Treatment Furnace 50~300T 11 Units
Split Furnace 80T 1 Unit
Differential Quenching Furnace 80T 1 Unit
Horizontal Boring Machine 8,000L 4,000H 6 Units 14
Horizontal Lathe 60T 5 Units

DOOSAN FORGED STEEL ROLLS


Machining
Horizontal Lathe 280T 2 Units
Shop
Grinding Machine 200T 1 Unit
Plano Miller 200T 4 Units
Cooling Equipment 8T 1 Unit
1. Melting
Induction Heating & 15T 2 Units
1 3 2. Forging Hardening Equipment
3. Differential Quenching Sub-Zero Equipment 8T 2 Units
Machine (80T) Work Roll Lathes 10T 5 Units
Shop Grinding Machine 10T 4 Units
2 4 4. Finish Machining

5. Skid Packing
Plano Miller 10T 1 Unit
Milling Machine 10T 2 Units
5 Auto UT Equipment 8T 1 Unit
QualityAssurance
Doosan is dedicated to producing rolls which meet or exceed
16

DOOSAN FORGED STEEL ROLLS


applicable codes, standards and customers’s specifications.

As a result of its unreserved efforts to guarantee product quality,


Doosan Heavy Industries & Construction Co., Ltd.
acquired ISO 9001 certification for its 24 products including rolls
used in power generation facilities and industrial plants in 1993.
R&D RESEARCH & DEVELOPMENT
18

DOOSAN FORGED STEEL ROLLS


D
A B C E

A. Thermal Shock Cracking


Evaluation of thermal shock resistance of roll materials
Relation between thermal shock crack depth and hardness, quenching temperature

B. Rolling Contact Fatigue


Evaluation of rolling contact fatigue life
Relation between hertzian stress and number of rolling contact

C. Wear Resistance
Evaluation of wear resistance
Comparison of wear resistance in roll materials
Ra change during rolling

D. Fracture Toughness
Evaluation of fracture toughness

E. Metallography / Analysis Apparatuses


Examination of the microstructure and fracture surface
TEM(Transmission Electron Microscope), AES(Auger Electron Spectroscopy),
SEM(Scanning Electron Microscope)