J Fail. Anal. and Preven.
(2014) 14:707–714
DOI 10.1007/s11668-014-9885-4
CASE HISTORY—PEER-REVIEWED
Ribbon Fatigue Spalling of a Forged Work Roll Used at a Cold
Rolling Mill
Soma Ghosh • Pankhuri Sinha • Shivanandan Indimath
Goutam Mukhopadhyay • Sandip Bhattacharya
Submitted: 29 May 2014 / in revised form: 13 September 2014 / Published online: 31 October 2014
Ó ASM International 2014
Abstract Catastrophic failure of a forged work roll used
in a cold rolling mill was investigated. The spalled roll
showed fatigue arrest marks in a smooth continuous path
along the circumferential direction. Characteristic features
of the fracture surface were similar to that of surface ini-
tiated spalling which is known as ribbon fatigue spalling.
The investigation consisted of visual observation, profiling
of crack using ultrasonic testing, microstructural charac-
terization by optical and scanning electron microscopy,
XRD analysis, and hardness measurements. Ultrasonic
evaluation confirmed the initiation of root crack on the roll
surface followed by an extensive sub-surface propagation
(*815 mm length) of fatigue crack. Microstructural ana-
lysis revealed the presence of dendritic columnar structure
and coarse irregular carbides indicating improper manu-
facturing process. Retained austenite content (*12%) as
measured using XRD was higher than the usual desirable
limit for such application. These microstructural abnor-
malities deteriorated the fatigue resistance of the roll. Since
the roll failed within few hours of the running campaign
and there was no operational abnormality reported in the
campaign, it can be inferred that the initiation of the fatigue
crack was conceived prior to the running campaign. It was
an inspection deficiency that the crack was not detected
prior to the start of the campaign. Initiation of fatigue crack
which could not be detected during inspection led to the
premature failure of roll in the early stage of campaign.
S. Ghosh (&)
P. Sinha
S. Indimath
G. Mukhopadhyay

S. Bhattacharya
R&D and Scientific Services, Tata Steel Ltd.,
Jamshedpur 831001, Jharkhand, India
e-mail: soma.ghosh@tatasteel.com;
soma2511ghosh@gmail.com
•
Keywords Fatigue
Ultrasonic
Metallography
Introduction
The work rolls used for cold rolling applications require
excellent resistance to wear and plastic deformation as it
performs under stern conditions thereby being exposed to
severe thermal and mechanical shock [1]. The quality of
work roll directly influences the overall production of the
mill. In-service failure of roll causes huge loss of capital as
well as adversely affects production increasing the down-
time. Improvements in roll qualities have therefore been a
challenging task for roll manufacturers over years. Now-a-
days, forged and induction-hardened alloy steel (3–5%
chromium) is being used as a superior material for work
rolls of cold rolling mills [2]. Forged and hardened work
roll grades offer improved fatigue resistance properties.
Manufacturing of forged rolls involves series of steps prior
to forging. This includes electric arc furnace melting, ladle
refining, ingot casting, and electro slag remelting (ESR)
process. Induction hardening of forged rolls helps in
achieving high surface hardness. Additionally, the addition
of chromium improves the hardenability and enhances the
wear resistance.
Despite careful attention from roll manufacturer and
user, roll failures do occur in service which lead to partial
or total loss of the rolls and even result in subsequent
damage to the rolling equipment apart from the huge pro-
duction loss.
Spalling is one of the prime causes of failure of forged
and hardened work rolls. Spalling is of two types
depending on its origin, viz.: surface and sub-surface.
Surface-initiated spalling is mostly related to operational
factors (strip breakage, thermal gradient, severe bruising,
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and improper grinding), whereas sub-surface-initiated
spalling is mostly an outcome of poor material quality
(improper grade, casting defects, non-metallic inclusions,
and improper heat treatment) [1–3].
In the present study, failure analysis of a forged steel
work roll, used in the skin pass unit of a cold rolling mill,
of an integrated steel plant has been presented. The skin
pass rolling as the last stage in the process chain of cold
rolling has gained importance due to the increased
demands of cold-rolled strips in terms of mechanical
properties and surface quality. The bottom work roll of
single stand 4-Hi skin pass mill at the referred Cold Rolling
Mill failed catastrophically in service resulting in several
hours of production loss. The primary aim of this investi-
gation is to establish the root cause of failure and to suggest
suitable measures so as to avert the reoccurrences of sim-
ilar failure in the future.
Visual Inspection and the Details of Roll
The new roll was supplied in the forged and induction-
hardened condition as per the requirements of the mill. The
surface hardness of the new roll was measured to be 93–95
Shore D (*825–862 HV). The initial size of roll was
U555 mm 9 1420 mm. The diameter of the failed roll was
measured to be 525 mm. The scrap diameter was 500 mm;
therefore, the roll consumed about 64% of the total
working depth. The concerned mill demanded almost
constant surface hardness of roll up to the scrap diameter
for stable rolling operation. The minimum required surface
hardness at the scrap diameter is 89–90 Shore D (*761–
774 HV) below which the roll is rejected at the mill.
A general view of the spalled roll is shown in Fig. 1a.
The total extent of the spalled region was measured to be
around 970 mm in the circumferential direction and
500 mm in longitudinal direction. The spalled region was
located at the edge of the drive side of the roll. A closer
view of the spalled region revealed a central narrow track
with fatigue arrest marks or beach marks as shown in
Fig. 1b, c. The observed features were similar to that of
surface-initiated spalling of a roll where fatigue arrest
marks and fan-shaped fracture flow lines were observed on
fatigue fracture face [4]. Spalling with these characteristics
has been termed as ‘‘Ribbon Fatigue Spalling’’ in some
literature [5]. In such spalling, surface-initiated crack
propagates in a non-radial direction and opposite to the
direction of rotation of roll. The fracture band more so ever
propagates progressively in a circumferential direction
running more or less parallel to the barrel of the roll [6]. In
the present case, a track of beach marks propagated in the
circumferential direction, opposite to the rotation of roll as
shown in Fig. 1c. Fatigue wreck path covered entire width
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J Fail. Anal. and Preven. (2014) 14:707–714
of spalled zone *500 mm. At both the sides of the track,
chevron marks projecting outward were observed as shown
in Fig. 1b, c. The chevron marks indicated final failure of
roll under brittle mode. Visual observation did not reveal
any kind of surface abnormality or tool mark on the barrel
portion of the failed roll. Data on the roll force which is an
important operational parameter to identify any kind of
deviation from the regular operating condition of the mill
was examined at the mill. The data confirmed the fact that
no abnormal fluctuation of load or overload encountered in
service prior to the catastrophic failure.
In ribbon fatigue spalling, root crack for fatigue wreck
path initiates somewhere on the roll surface. Ultrasonic
evaluation of the failed roll was performed to validate the
fact. A portion from the spalled region was collected for
material analysis (Fig. 1d). The sample was representative
of typical features of surface-initiated spalling observed in
the failed roll. Region of fast fracture as well as fatigue
path was observed in the sample as marked in Fig. 1d–f.
Detailed characterization comprising of chemical analysis,
optical and scanning electron microscopy, XRD analysis,
and hardness measurement were carried out on the repre-
sentative sample.
Ultrasonic Inspection
A conventional portable ultrasonic testing machine was
used for the purpose. A 2-D raster scan was performed over
the surface of the un-spalled region of the roll with a
4 MHz normal beam probe in the pulse-echo mode. Details
of ultrasonic inspection parameters are given in Table 1.
The data obtained from A-Scan peaks (time of flight and
amplitude) were used to develop the crack profile in the
sub-surface region of roll.
Due to the inherent dead zone of a normal beam probe,
profiling of the crack is not possible for depths less than
6 mm. Therefore, a 4 MHz TR probe was used once the
echoes for the crack were detected at depths less than
6 mm. A generic profile (Fig. 2) of the crack propagation
in the sub-surface region of roll was obtained using the data
of ultrasonic evaluation.
The crack profile as shown in Fig. 2 suggested the root
crack to be present on the surface of the roll. This crack
(primary surface crack as marked in Fig. 2a) was then
visually identified at a distance of approx. 270 mm from
the edge of the barrel of roll at the drive side. It can be
inferred from the above analysis that the primary surface
crack initiated on the surface and gradually propagated
toward the skin–core interface. The crack then extended in
the visible spalled region on reaching the skin–core inter-
face (Fig. 2b). The extent of the crack in the sub-surface
region was found to be of approx. 315 mm in length along
J Fail. Anal. and Preven. (2014) 14:707–714
Fig. 1 (a) Overall view of failed roll, (b, c) View of spalled region, (d–f) View of representative sample used for analysis
the barrel circumference and then continued in the visible
spalled region. The total crack length was approx. 815 mm
(combining both visible crack and sub-surface crack).
Chemical Analysis
Chemical analysis of a sample from the spalled region of
failed roll was carried out using inductively coupled
plasma (ICP) spectrometer (Germany, model: ARCOS);
carbon (C) and (S) contents of the sample were determined
709
using combustion infrared technique (LECO, TC600) as
per standard IS 228 Part 20. The obtained results of the
chemical analysis are compiled in Table 2. The chemical
composition of the roll was found to be typical of any 5%
chrome-forged grade.
Macro- and Microstructural Analysis
Small specimens were cut from the roll sample for macro-
and microstructural examinations. The specimens were
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mounted with resin, ground, and polished using standard specimen was further confirmed using XRD. Fine carbides
metallographic technique. The polished sample was etched were observed to be more or less well distributed in the
with Vilella’s solution (4 g picric acid, 100 mL ethanol, matrix. Elongated carbides in the form of chains as well as
5 mL hydrochloric acid) to reveal the microstructure. Both coarse angular carbide particles were observed at few
macro- and microstructural analyses were done using an locations as shown in Fig. 3c, d. Coarse angular and
optical microscope (LEICA DMRX). The optical macro- elongated morphologies of carbides are an outcome of
graph of roll is shown in Fig. 3a. Figure 3a reveals improper manufacturing process [9, 10] and undesirable for
columnar dendritic appearance indicating unbroken cast prolonged roll life [2]. However, phase fraction (%) of
structure. Improper forging or low forging ratio during elongated and coarse carbides was very less (\1%) and
manufacturing stage promotes this type of cast structure [7, could not be considered sufficient enough to assist in the
8]. Cast structure is not desirable for present application as initiation and propagation of fatigue crack.
it decreases the fatigue resistance of roll drastically. Opti-
cal micrographs of the roll are shown in Fig. 3b–d.
Figure 3b reveals martensitic matrix appearing dark along Scanning Electron Microscopy and EDS Analysis
with some white regions. The white region seemed to be
retained austenite; the presence of which in the spalled The Vilella-etched roll specimen was analyzed using a
scanning electron microscope (Oxford Instrument) equip-
ped with EDS facility. Two fields were selected under SEM
Table 1 Details of ultrasonic inspection parameters
for analysis as shown in Fig. 4a, b. EDS spectrum of
Inspection parameter Details elongated carbide (as marked in Fig. 4a) and its composi-
tion are shown in Fig. 5. All the carbides (elongated
Flaw detector model & make USM/DMS Go, GE Sensing &
Inspection Technologies carbides, coarse angular carbides, and fine carbide precip-
Probe type Normal beam L-wave itates) were observed to have similar compositions; a
Probe size & frequency Ø10, 4 MHz typical of complex iron carbides.
Cable type LEMO-00 RT ANG/LEMO-00
Basic calibration block IIW V1
Couplant used Oil
XRD Analysis
Scanning technique Pulse-echo raster scan
X-ray diffraction measurements were carried out on inner
Range 0–100 mm
and outer surfaces of spalled sample. The sample was
Gain 64 dB
scanned from 35° to 90° with a step size of 0.02° in a

Fig. 2 (a) 2-D representation of overall spalled region on the work face of roll, (b) Schematic representation of crack propagation at the
subsurface zone in unspalled region

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J Fail. Anal. and Preven. (2014) 14:707–714 711

Table 2 Chemical analysis of the roll sample (wt.%)

Sample C Mn S P Si V Al Cr Mo Cu Ni Fe

Roll 0.90 0.30 0.005 0.020 0.67 0.16 0.015 4.90 0.24 0.06 0.37 Bal.

Fig. 3 (a) Optical macrograph of roll specimen, (b–d) Optical micrographs of roll specimen

Fig. 4 (a, b) SEM images of roll sample

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Fig. 5 EDS spectrum of location 1(carbide) as marked in Fig. 4a
Fig. 6 XRD pattern at inner surface of spalled roll specimen
Panalytical XRD-MPD system using Cu Ka radiation.
Quantification was done with the help of Xpert Highscore
plus software. XRD pattern at the inner surface of spalled
specimen as shown in Fig. 6 reveals peaks of austenite and
martensite. Volume fractions of retained austenite using X-
ray diffraction were calculated to be approximately 12% at
both the surfaces which is higher than the desirable limit
for induction-hardened roll. The usual acceptable limit for
retained austenite in the induction-hardened grade is
between 5 and 10% as reported by Patt et al. [11].
Hardness Measurements
Microhardness as well as bulk hardness profile in the radial
direction of the spalled sample was plotted. The microh-
ardness was measured in a pneumatically controlled
automatic microhardness tester (Leco-LM247AT). A load
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J Fail. Anal. and Preven. (2014) 14:707–714
Fig. 7 Microhardness profile of roll
Fig. 8 Bulk hardness profile of roll
of 100 gf was used for microhardness testing. Bulk hard-
ness values were measured in a Vickers hardness testing
machine using 30-kg weight. Five indents were taken to get
the average hardness value for a particular zone. Micro- and
macrohardness profiles are shown in Figs. 7 and 8,
respectively. Both profiles (Figs. 7, 8) show gradual drop of
hardness from surface (skin) toward the inner region. As per
user’s requirements, the referred roll, if not failed, could
have consumed additional 25-mm diameter before being
scrapped. The surface hardness at the scrap diameter should
not be less than 761 HV (*89 Shore D) according to the
requirement of mill mentioned earlier. However, the hard-
ness profiles (Figs. 7, 8) indicate that the hardness at the
scrap diameter is lower than the specified limit. Addition-
ally, rapid decrease of hardness representing a sharp
gradient in hardness was present from the roll surface up to
the scrap diameter. In a typical induction-hardened roll with
an almost constant surface hardness within the working
diameter, the hardness starts dropping below the working
zone/depth [12]. A sharp gradient in hardness is present in
the interfacial region between the hardened skin and the soft
core in the typical roll. However, the sharp drop of hardness
present within the usable diameter or thickness in the failed
roll indicates improper manufacturing of the roll which was
unfavorable for the performance.
Discussion
Analysis of in-service catastrophic failure of a work roll in a
cold rolling mill of an integrated steel plant has been
J Fail. Anal. and Preven. (2014) 14:707–714
presented. The roll failed prematurely after giving 64% of
its service life. Visual observation of the failed roll revealed
a huge spalled region of about 970 mm 9 500 mm. Frac-
ture surface consisted of a narrow track with fatigue arrest
marks or beach marks which propagated in the direction
opposite to the rotation of roll. Chevron marks were
observed projecting outward on both sides of the fatigue
track indicating final fracture in brittle mode. Overall fea-
tures observed on the fracture surface were typical to that of
ribbon fatigue spalling [5] wherein root crack initiated on
the surface.
Ultrasonic testing (UT) confirmed the presence of root
crack on the surface, from where the fatigue crack propa-
gated. The root crack was found to originate from shell
surface and then propagated gradually inside causing vis-
ible spall after certain length. Observation indicated that
fatigue crack propagated both radially and circumferen-
tially. This was in agreement with the findings of
Pantazopoulos et al. [13]. Qiong et al. [4] have reported
about the possible mechanisms of surface initiation of
spalling in their work. Operational overload or localized
region of stress concentration due to the presence of defect
like roll mark can lead to the initiation of crack. Once the
crack initiates, it grows at a low angle to the working
surface under the tangential force. The crack readily
propagates at higher angle with increase in its depth under
the shear stress. After a certain depth along the crack when
the maximum shear stress reaches, the final failure takes
place.
Detailed metallurgical analysis was carried out using a
small portion from the spalled sample. Chemical analysis
revealed the material composition to be typical of any 5%
chrome-forged roll. However, macrostructure revealed
columnar dendritic region, a signature of inadequate
deformation imparted during forging in the manufacturing
stage. Optical microstructure of the roll sample revealed
tempered martensitic matrix with fine globular carbide
precipitates. Elongated as well as coarse angular carbides
were observed at few locations which indicated improper
morphology of carbides. Such morphologies are not
desirable for prolonged service life of roll [2]. Retained
austenite which increases spalling tendency was observed
in high proportion (*12%). A sharp gradient in hardness
was observed to be present within the working diameter of
roll which is detrimental. Overall microstructural analyses
confirmed poor material quality of roll in terms of fatigue
resistance. However, the possible reasons of surface-initi-
ated spalling as discussed earlier emphasize on the gaps in
the mill operating conditions. Such abnormalities in oper-
ating conditions in the present case can be operational
overload or roll mark. Material abnormality observed in the
failed roll has resulted in fast propagation of fatigue crack
due to poor fatigue resistance. It can be apprehended that
713
either the crack initiated due to operational overload
(excessive radial contact roll pressure) or roll mark or the
crack was not completely removed during the last dressing.
Possibility of surface crack initiation due to roll mark was
ruled out as no roll mark was observed on the roll surface.
Additionally, no abnormality in the operation was reported
during the running campaign. The fact that roll failed under
extensive propagation of fatigue crack (&815 mm-length)
within few hours of operation during the running campaign
indicated that the root crack was present even after the last
dressing due to some inspection deficiencies.
Conclusion
Analysis of the above roll resulted in following
conclusions:
1. The roll spalled due to initiation of fatigue crack from
the surface because of mill abnormality.
2. The propagation of fatigue crack which was not
detected during inspection ultimately led to cata-
strophic failure of the roll.
3. Inadequate forging and improper heat treatment of the
roll resulted in poor material quality which aggravated
the spalling.
Recommendation
Ribbon fatigue spalling being a fault from user of roll
rather than the manufacturer’s side can be prevented by
regular inspection. Practice of NDT techniques, e.g., Eddy
current or Ultrasonic inspection after every grinding
operation can detect any surface damage thereby prevent-
ing such premature failure.
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