Cost-effective repair solution for twin-roll-caster rollers

Abstract. Twin-Roll-Casting (TRC) is an energy- and cost-efficient process to produce near-net-shape aluminum strips. Due to the high affinity of molten aluminum to steel surfaces, those rollers show signs of wear throughout the rolling campaign. This leads to the necessity of restoring the worn surfaces to suitable parameters. The easiest way is to grind the surface till all superficial defects are omitted. However, the thickness of the roller is not endless, therefore the rollers must be replaced after a certain amount of surface reconditioning. This ultimately leads to the non-usability of the roller. This research shows a route to recondition the surface including the possibility of renewing worn-down surfaces with an energy- and cost-efficient high-velocity oxygen fuel (HVOF) treatment with subsequent grinding to the desired initial surface parameters.