MECHANISMS OF LARGE PARTICLE SPALLATION IN THERMAL FATIGUE OF HIGH-CHROMIUM TOOL STEEL
Keywords:
thermal fatigue, high-Cr steel, oxidation-assisted cracking, large particle spalling
Abstract
High-chromium steels used for hot rolling work rolls are exposed to severe cyclic thermal and mechanical loads, which often lead to unexpected early failure due to large particle spalling. This study investigates the mechanisms of oxidation-assisted cracking that promote early spallation under thermal fatigue conditions. Laboratory tests were performed on centrifugally cast high-chromium steel using a thermomechanical simulator to replicate harsh oxidation and cyclic heating environments. Microstructural analysis revealed that eutectic carbides and chromium-depleted regions are particularly susceptible to oxidation, accelerated crack initiation and growth. Three distinct modes of crack linking were identified as critical pathways for large particle spalling: (Mode 1) direct linking of radial cracks, (Mode 2) linking of radial cracks via lateral cracks, and (Mode 3) linking of radial cracks via oxidized eutectic carbides. The results highlight combined influence of oxidation, carbide network arrangement, and thermal stress on early spallation of large particles, providing new insights into roll surface degradation and potential directions for improving roll lifetime in industrial hot rolling.
References
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2. A. K. Tieu, Q. Zhu, H. Zhu, C. Lu, An investigation into the tribological behaviour of a work roll material at high temperature, Wear, 273 (2011), 43-48, doi: 10.1016/j.wear.2011.06.003
3. W. F. H. Zamri, P. B. Kosasih, A. K. Tieu, Q. Zhu, H. Zhu, Variations in the microstructure and mechanical properties of the oxide layer on high speed steel hot rolling work rolls, J. Mat. Pro. Tec., 212 (2012), 2597-2608, doi:10.1016/j.jmatprotec.2012.07.007
4. N. F. Garza-Montes-de-Oca, W. M. Rainforth, Wear mechanisms experienced by a work roll grade high speed steel under different environmental conditions, Wear, 267 (2009), 441-448, doi: 10.1016/j.wear.2009.01.048
5. O. Joos, C. Boher, C. Vergne, C. Gaspard, T. Nylen, F. Rezaï-Aria, Assessment of oxide scales influence on wear damage of HSM work rolls, Wear, 263 (2007), 198-206, doi: 10.1016/j.wear.2007.02.005
6. D. Bombač, M. Gintalas, G. Kugler, M. Terčelj, Mechanisms of oxidation degradation of Cr12 roller steel during thermal fatigue tests, Metals, 10 (2020) 4, 450, doi: 10.3390/met10040450
7. C. Wei, S. Song, Y. Zhang, Q. Ke, Y. Tian, A novel method for competitive failure behavior and mechanical degradation online monitoring of laser additive work roll under multidimensional damage, Eng. Fail. Anal., 157 (2024), 107897, doi: 10.1016/j.engfailanal.2023.107897
8. J. Lu, L. Hao, P. Wang, H. Huang, X. Li, C. Hua, L. Su, G. Deng, Wear prediction model of hot rolling backup roll based on FEM + ML algorithm, Int. J. Adv. Manuf. Technol. 131 (2024), 5923-5939, doi: 0.1007/s00170-024-13311-6
9. X. Hu, X. Zhou, H. Liu, H. Song, S. Wang, H. Zhang, Enhanced predictive modeling of hot rolling work roll wear using TCN-LSTM-Attention, , Int. J. Adv. Manuf. Technol. 131 (2024), 1335-1346, doi: 0.1007/s00170-024-13105-w
10. Y. Min, B. Jens, X. Wu, L. Xu, Oxidation and Thermal Fatigue Behaviors of Two Type Hot Work Steels During Thermal Cycling, J. Iron Steel Res. Int., 20 (2013), 90-97, doi: 10.1016/S1006-706X(13)60202-2
11. R. Colas, J. Ramirez, I. Sandoval, J. C. Morales, L. A. Leduc, Damage in Hot Rolling Work Rolls, Wear, 230 (1999) 1, 56-60, doi: 10.1016/S0043-1648(99)00081-2
12. N. F., Garza-Montes-de-Oca, R. Colás, W. M. Rainforth, High temperature oxidation of a work roll grade high speed steel, Oxid. Met. 76 (2011), 451-468, doi: 10.1007/s11085-011-9266-2
13. J. H. Ramírez-Ramírez, R. Colás, N. F. Garza-Montes-de-Oca, High temperature oxidation of a work roll grade high-chromium white cast iron, J. Iron Steel Res. Int. 20 (2013), 122-129, doi: 10.1016/S1006-706X(13)60187-9
14. D. N. Hanlon, W. M. Rainforth, The rolling sliding wear response of conventionally processed and spray formed high speed steel at ambient and elevated temperature, Wear, 255 (2003), 956-966, doi: 10.1016/S0043-1648(03)00083-8
15. M. Pellizzari, A. Molinari, G. Straffelini, Tribological behaviour of hot rolling rolls, Wear, 259 (2005), 1281-1289, doi: 10.1016/j.wear.2004.12.006
16. X. Ren, H. Fu, J. Xing, Y. Yi, Research on high-temperature dry sliding friction wear behavior of Ca–Ti modified high boron high speed steel, Tribo. Int. 132 (2019), 165-176, doi: 10.1016/j.triboint.2018.12.009
17. H. Torres, M. Varga, F. Widder, U. Cihak-Bayr, O. Viskovic, M. Rodrígez Ripoll, Experimental simulation of high temperature sliding contact of hot rolled steel, Tribo. Int., 93 (2016), 745-754, doi: 10.1016/j.triboint.2015.01.007
18. Y. Lao, H. Du, T. Xiong, Y. Wang, Evolution Behaviors of Oxides in Severely Plastic Deformed Region of AISI 52100 Steel during Dry Sliding Wear, J. Mat. Sci Tec., 33 (2017) 4, 330-337, doi: 10.1016/j.jmst.2016.06.001
19. D. Bombač, M. Gintalas, G. Kugler, M. Terčelj, Thermal fatigue behaviour of Fe-1.7C-11.3Cr-1.9Ni-1.2Mo roller steel in temperature range 500–700 °C, Int. J. Fat., 121 (2019), 98-111, doi: 10.1016/j.ijfatigue.2018.12.007
20. H.T. Zhu, A.K. Tieu, L.H. Su, M. Reid, L. Zhang, P.T. Wei, X. Zhao, H. Wang, J. Zhang, J.T. Li, T.D. Ta, Q. Zhu, C. Kong, Q. Wu, Theoretical and experimental investigation of thermal and oxidation behaviours of a high speed steel work roll during hot rolling, Int. J. Mech. Sci., 131-132 (2017), 811-826, doi: 10.1016/j.ijmecsci.2017.08.024
21. Q. Zhu, H. T. Zhu, A. K. Tieu, M. Reid, M. L. C. Zhang, In-situ investigation of oxidation behaviour in high-speed steel roll material under dry and humid atmospheres. Cor. Sci., 52 (2010), 2707-2715, doi: 10.1016/j.corsci.2010.04.027
22. M. J. Monteiro, S. R. J. Saunders, F. C. Rizzo, The Effect of Water Vapour on the Oxidation of High Speed Steel, Kinetics and Scale Adhesion, Oxid. Met., 75 (2011), 57-76, doi: 10.1007/s11085-010-9220-8
23. N. F. Garza-Montes-de-Oca, R. Colás, W. M. Rainforth, On the damage of a work roll grade high speed steel by thermal cycling, Eng. Fail. Anal., 18 (2011), 1576-1583, doi: 10.1016/j.engfailanal.2011.06.001
24. D. Bombač, G. Kugler, J. Burja, M. Terčelj, Early Spalling Analysis of Large Particles in High-Cr Steel during Thermal Fatigue: Relevant Mechanisms, Materials, 15 (2022) 19, 6705, doi: 10.3390/ma15196705
25. D. Bombač, G. Kugler, B. Markoli, M. Terčelj, Hot work roller surface layer degradation progress during thermal fatigue in the temperature range 500–700 °C, Int. J. Fat., 104 (2017), 355-365, doi: 10.1016/j.ijfatigue.2017.08.008
Published
2026-04-09
How to Cite
1.
Burja J, Kugler G, Terčelj M, Bombač D. MECHANISMS OF LARGE PARTICLE SPALLATION IN THERMAL FATIGUE OF HIGH-CHROMIUM TOOL STEEL. MatTech [Internet]. 2026Apr.9 [cited 2026Jul.14];60(2):293–297. Available from: https://mater-tehnol.si/index.php/MatTech/article/view/1629
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