Roll mills chemical composition optimization applications with computational materials engineering technology

Rolls are among the most critical equipment for rolling mills, playing a vital role in ensuring production safety and cost optimization. While rolling mills prefer rolls that offer both cost-effectiveness and high performance, roll manufacturers face increasing production costs and are in search of innovative solutions. Reducing roll costs requires the optimization of alloying element quantities. However, producing and testing these chemical compositions through trial-and-error methods poses significant disadvantages in terms of both time and cost. This study aimed to test the suitability of suitable chemical compositions by designing them according to the desired microstructure features using the CALPHAD (CALculation of PHAse Diagrams) technique within the framework of computational materials engineering. This method optimizes the amount and distribution of carbide, cementite, and graphite phases. After the roll castings were performed on the calculated compositions, microstructure examinations, carbide determinations, wear tests, and surface roughness measurement studies were carried out. The obtained results provide an approach that will both meet rolling mills' demands and improve cost and production processes. This study shows the advantages of the CALPHAD technique in rolling roll design and offers an innovative solution in materials engineering.