Internal cracks and non-metallic inclusions as root causes of casting failure in sugar mill roller shafts

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dc.contributor.authorJamil, Muhammad
dc.contributor.authorKhan, Aqib Mashood
dc.contributor.authorHegab, Hussien
dc.contributor.authorSarfraz, Shoaib
dc.contributor.authorSharma, Neeraj
dc.contributor.authorMia, Mozammel
dc.contributor.authorGupta, Munish Kumar
dc.contributor.authorZhao, GuLong
dc.contributor.authorMoustabchir, H.
dc.contributor.authorPruncu, Catalin I.
dc.date.accessioned2019-09-19T18:10:31Z
dc.date.available2019-09-19T18:10:31Z
dc.date.issued2019-08-03
dc.description.abstractThe sugar mill roller shaft is one of the critical parts of the sugar industry. It requires careful manufacturing and testing in order to meet the stringent specification when it is used for applications under continuous fatigue and wear environments. For heavy industry, the manufacturing of such heavy parts (>600 mm diameter) is a challenge, owing to ease of occurrence of surface/subsurface cracks and inclusions that lead to the rejection of the final product. Therefore, the identification and continuous reduction of defects are inevitable tasks. If the defect activity is controlled, this offers the possibility to extend the component (sugar mill roller) life cycle and resistance to failure. The current study aims to explore the benefits of using ultrasonic testing (UT) to avoid the rejection of the shaft in heavy industry. This study performed a rigorous evaluation of defects through destructive and nondestructive quality checks in order to detect the causes and effects of rejection. The results gathered in this study depict macro-surface cracks and sub-surface microcracks. The results also found alumina and oxide type non-metallic inclusions, which led to surface/subsurface cracks and ultimately the rejection of the mill roller shaft. A root cause analysis (RCA) approach highlighted the refractory lining, the hot-top of the furnace and the ladle as significant causes of inclusions. The low-quality flux and refractory lining material of the furnace and the hot-top, which were possible causes of rejection, were replaced by standard materials with better quality, applied by their standardized procedure, to prevent this problem in future production. The feedback statistics, evaluated over more than one year, indicated that the rejection rate was reduced for defective production by up to 7.6%.en_UK
dc.identifier.citationJamil M, Khan AM, Hegab H, et al., Internal cracks and non-metallic inclusions as root causes of casting failure in sugar mill roller shafts. Materials, Volume 12, Issue 15, 2019, Article number 2474en_UK
dc.identifier.issn1996-1944
dc.identifier.urihttps://doi.org/10.3390/ma12152474
dc.identifier.urihttps://dspace.lib.cranfield.ac.uk/handle/1826/14546
dc.language.isoenen_UK
dc.publisherMDPIen_UK
dc.rightsAttribution 4.0 International*
dc.rights.urihttp://creativecommons.org/licenses/by/4.0/*
dc.subjectroot cause analysisen_UK
dc.subjectnon-destructive testingen_UK
dc.subjectdestructive testingen_UK
dc.subjectoptical inspectionen_UK
dc.subjectmicroscopyen_UK
dc.subjectrejection rateen_UK
dc.subjectheavy manufacturing industryen_UK
dc.titleInternal cracks and non-metallic inclusions as root causes of casting failure in sugar mill roller shaftsen_UK
dc.typeArticleen_UK

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