Journal of Advanced Materials in Engineering

Journal of Advanced Materials in Engineering

Comprehensive Failure Analysis of Rollers Screen Used in Iron Ore Pelletizing Plants

Document Type : Original Article

Authors
Maryam Karbasi 1
Amir Karimi 1
Sobhan Saadat 2
Hamid Talebizadeh Sardari 2
Ali Mirzaei 1
1 Department of Materials Engineering, Isfahan University of Technology, Isfahan, Iran
2 Nazm Avaran Sanat va Madan Gol Gohar Company, Sirjan, Iran
10.47176/jame.45.2.1114
Abstract
Introduction and Objectives: This study investigates the failure mechanisms of three types of rollers used in iron ore pelletizing plants, namely 304 stainless steel, 1.4313 steel, and hard chrome-coated St52 steel. The objective is to identify the causes of failure and assess the suitability of these materials for industrial application.
Materials and Methods: The failure analysis was conducted using macroscopic and statistical classification, hardness testing, quantometer analysis, scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS). These methods enabled a comprehensive evaluation of the mechanical, structural, and surface characteristics of the rollers.
Results: The results indicated that 304 stainless steel rollers failed due to low yield strength and insufficient hardness (~210 HV), leading to mechanical deformation and wear. In 1.4313 steel, widespread pitting corrosion and microstructural inhomogeneity caused excessive surface roughness and twisting. For the hard chrome-coated St52 rollers, the excessive coating thickness (up to 200 µm) resulted in brittle, detached layers that cracked at the interface, causing severe local delamination during operation.
Conclusion: The study reveals that failure mechanisms vary depending on the material properties and coating processes. Understanding these differences can inform better material selection and manufacturing practices, potentially extending the service life and improving the efficiency of roller components in pelletizing operations.
Keywords
Failure analysis
Mechanical deformation
Roller
Pitting corrosion
Steel
Subjects
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Journal of Advanced Materials in Engineering
Volume 45, Issue 2
2026
Pages 1-21

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