Connecticut Steel First to Use Fourth Generation Binder Grade

To address the unique quandary facing Connecticut Steel Corporation (CSC), SinterMet developed an equally unique solution customized expressly for this mill based in Wallingford,Connecticut.

CSC is a welded wire reinforcement 15 stand Morgan bar/wire mill with a 10 stand Morgan No-Twist finishing block. CSC produces 300,000 tons a year of low-, medium-and high carbon rod.The company also produces wire rod by drawing or cold rolling to produce rolls,sheets and structural welded wire reinforcement.

To facilitate the manufacture of .2187 ”-.50 ”wire rod, wire mesh and #3 and #4 rebar in coils, CSC utilizes various grades of SinterMet ’s carbide rod mill rolls for the finishing block.

“Connecticut Steel previously used our third generation SM-63 10% binder grade tungsten carbide rolls in the finishing stands of the rod block,” explains Bill Posey, regional sales manager at SinterMet. The third generation features an optimized cobalt-nickel-based binder along with a modified tungsten carbide hard phase and combines high toughness, corrosion resistance, impact resistance and heat checking resistance.

“The roll performance using SM-63 was excellent, but because the last two stands are so critical to CSC ’s product, their mill was consistently shutting down to change rolls,” says Bill. Shutdowns were creating problems for CSC, which serves markets in the Northeast, Mid-West and Mid-Atlantic states.

To determine the optimum grade for their operation, SinterMet evaluated CSC’s mill parameters, including the shape of their products, the speed of their operation, cooling conditions,machining capabilities and reduction per stand.

SinterMet developed its fourth generation SM-80N 7% binder grade specifically to address CSC ’s problem. When compared to the performance of the third generation grade, the fourth generation provides even greater impact resistance and improved heat checking and corrosion resistance.

With initial installation in April 2001, the use of SM-80N has doubled the mill ’s roll wear performance versus its performance when SM-63 was used. “This is an incredible increase in throughput,” says Bill.

“Connecticut Steel is obviously extremely pleased. I ’m confident that they ’ll continue to perform at an optimal level,” adds Bill. “We ’re looking forward to evolving the business relationship and addressing future concerns with a solution that directly meets their needs.”