2007 SECTION 1, PART A, SA-640/8A-649M, SPECIFICATION FOR FORGED STEEL ROLLS USED FOR CORRUGATING PAPER MACHINERY SY SA-649) as dential with ASTM Sp 1. Scope L1_ This specification covers two kinds of rolls used in machinery for producing corrugated paperbosrd, Rolls are fabricated of forged bodies and trunnions, The trun- nions may be bolted or shrink assembled on one oF both ends of the body. A seal weld may be made at the body/ trunnion interface. Roll shells are made of carbon/manga- nese, or low alloy steel as hereinafter described, and are hhcat treated prior to assembly, Pressure rolls are surface hardened, Provision is made in Supplementary Reguire- ‘ment $1 for the optional surface hardening of corrugat- ing rolls. 1.2. Cotrugating and pressure rolls made to this specifi- cation shall not exceed 30 in, [760 mam in inside diameter ‘The wall thickness of the roll body shall not be less than Ja of the inside diameter or 1 in. [25 mm, whichever is greater, but shall not exceed 4 in, (100 mm}. The wall thickness of the corrugating roll is measured at the bottom of the cortugations in the location of the twnnion fit, The maximum design temperature (MDT) of the roll is 600°F (315°C) and the maximum allowable working pressure (MAWP) is 250 psi [1.7 MPa}. The mininwam design tem: perature shall be 40°F [4°C] for roll wall thicknesses up fo 3 in, [75 mm). For roll wall thicknesses over 3 in. (75 mm] fo 4 in, (100 mm), the minimum design tempera ture shall be 120°F [50°C]. The maximum stresses of the roll bodies from the combined internal an external Toading, are limited to 18 750 psi [129 MPa for the Class 2 pressure roll bodies, and 20 000 psi {138 MPa] for Class 1A, 1B, (or 5 pressure or corugating rll bodies in Grades 1 or 2. For the trunnions, the maximum stresses from the combined internal and externa} loading are limited to 15 000 psi [103.4 MPa) for Classes 3 oF 4, or 20 000 psi [138 MPs} for Classes 1, 1B, or $ in Grade 2 only. ‘The Grade 1 strength level is not permissible for trunnions. 1.3 Referring to Table 1, material to Classes 1A, 1B, for 5 shall be used for the manufacture of corrugating of /S4-649M d reification A 6497 649-04) pressure roll shells, and Class 2 shall be used only for pressure roll shells. Trunnions shall be made from forgings in Classes 1A, 1B, or 5 in Grade 2 strength level as restricted by Footnote B in Table 2 or in forgings in either Class 3 or 4, 1.4 ‘The values stated in either inch-pound units or ST [metric} units are to be regarded separately as standards, ‘Within the text and tables, the ST units are shown in brack: ets. The values stated in each system are not exact equiva Tents; therefore, each system must be used independent of the other. Combining values from the two systems may result in nonconformance with the specification, 1L5_ Unless the order specifies the applicable “M” speci- fication designation, the material shall be furnished to the inch-pound units. 1.6 Except as specifically required in this standard, all of the provisions of Specification A 788 apply. 2. Referenced Documents 2.1 ASTM Standards. A.275/A 275M Test Method for Magnetic Particle Exami- nation of Steel Forgings A370 Test Methods and Definitions for Mechanical ‘Test- ing of Steel Products A788 Specification for Steel Forgings, General Require- ments E 165 Practice for Liquid Penetrant Examination 3. Ordering Information 3.1 Material supplied to this specification shall conform to the requirements of Specification A788, which outlines additional ordering information, manufacturing require ‘ments, testing and retesting methods and procedures, matk- ing, certification, product analysis variations and additional supplementary requirements. ums oSA-649/8A-649M 3.2. In addition to the ordering requirements of Specitfi- cation A788, the purchaser shall include the maximum, design temperature (MDT), if lower than 600°F [315 °Cl,, and the maximum allowable working pressure (MAWP), 250 psi [1.7 MPa] as allowed in 1.2 of the 3.3 Ifthe requirements of this specification are in con- flict with the requirements of Specification A 788, then the requirements of this specification shall prevail 4, Materials and Manufacture 4a. Forging Process: 4.1.1 Roll body forgings may be made as solid forg- ings and subsequently bored. 4.1.2 Trumnions or gudgeons which are to be subse: ‘quently assembled to form the rol] shall be made as a solid forging or where practical upset from segments cut from billets or bars, 42 Heat Treatment: 4.2.4 Heat Treatment for Mechanical Properties (Requirements do not apply to surface treatment): 42.1.1 Machining — The forged roll body shall have all surfaces rough machined, inchiding boring, prior (o heat treatment for mechanical properties. 42.1.2 Roll bodies shall be normalized, liguid uenched, and tempered to produce the required mechani- cal properties, except that for Class 2 forgings, and when Grade 2 strength requirements are specified, a normalize and temper heat ueatment may be applied. 4.2.1.3 ‘The wunnions shall be nosmelized and tem- pered or annealed to produce the required mechanical prop- enties. 4.2.2 Surface Hardening of Pressure Roll Forg ings — The working face of pressure rolls shall be surface hardened either before or after fitting the trunnions, at the manufacturer's option, 4.3 Assembly and Weld — Excopt fr integrally forged or boled-on unions, the assembly shall be made by shrink fing twunsions into the prepred body ends. If used, welding of the tunnion tothe rll body is restcted toa in. (8.5ran man sal weld, made wit ow hydrogen materials, A minimum preheat of 400°F [205°C] and a ‘minimum post weld heat treatment of 850°F [455°C] for shall be used. The maximum post weld heat retment ball be not higher thn 7 SO"F (1 ~ 28°C] where 1 the final tempering temperature. All welds shall be machined or ground forthe ial mapnetic particle or iui penetant examination 1174 2097 SECTION MT, PART A 5. Chemical Composition 5.1 The sfecl shall conform to the requirements for chemical composition prescribed in Table 1 6. Mechanical Properties GA Tensile Requirements 6.1.1 The material shall conform to the requirements for tensile properties prescribed in Table 2 when tested in accordance with Test Methods and Definitions A 370, Tension test specimens shall be the standard round in, [12.5 mm] diameter, 2 in, [50 mm) gage length. The yield steength preseribed in ‘Table 2 shall be determined by the 0.2% offset method, AAI Tests for acceptance shall be made after the heat reatment of the forgings, for mechanical properties in accordance with 4.2.1 6.1.2. Number, Location, and Orientation of Test pecimens 1.2.1 Roll Body Forgings — A full-size prolon- gation shall be provided on 2 roll body forging representing each heat of stecl in each heat-treatment furnace charge, ‘One longitudinal tension test specimen shall be taken from the prolongation and the axis of the specimen shall be located midway between the inner and outer surfaces of the wall body. 641.22 Trunnions — Test material shall be pro- vided from each heat of steel in each heat-treatment furnace charge. One longitudinal tension specimen shall be taken from each test piece and the axis of the specinen shall be located a any point midway between the center and surface of the solid forging. 6.22 Hardness 62.1 Roll body forgings shall have a Brinell hard~ ness from 352 HB to 415 HB (Grade 1) or 207 HB to 285 HB (Grade 2). No less than three hardness determinations shall be made on each roll. The hardness readings are t© be taken on the outside of the roll bodies using care to prepare locations for tests that are five of decarburization Dut not so deep as 00 affect the usefulness of the material 6.2.2 The surface hardened pressure roll body forg- ings shall have a hardness of 58 HRC to 65 HRC or equivalent, No less than three hardness determinations shall bbe made on each roll. The harness depth shall not exceed % (6 mm}. 7. Retreatment 7.1. Ifthe results of the mechanical tests of amy forging do not conform to the specified requirements, the manafinc- turer may retreat the forging one or more times, bat not2007 SECTION ‘more than three additional times without approval of the purchaser. 8. Magnetic Particle Examination 81 The entite surface of the roll, including the seal weld area, shall be examined by either a wet continuous ‘method in accordance with Test Method A 275/A 275M or by a liquid penetrant method in accordance with Prat E 165 after machining or grinding. The use of prods in the ‘magnetic particle method is not permitted, 82 Only indications with major dimensions greater than 4 in [3.2 mm] ate considered relevant. 83 Acceptance Standards — The following relevant indications are unacceptable: 8.3.1 Any linear indications greater then Ye in (4.8 mm} Jong, 8.3.2 Rounded indications greater than %¢ in, 48 mum 833. Four or more indications in a line separated by ig in, (1.6 mm] or less edge to edge 8.3.4 Ten or more indications in any 6 in? [38.71 em?) of surface. us PART A SA-649/8A-649M 9. Hydrostatic Testing 9.1. The machined roll assembly shall be hydrostatic tested at 1% times the maximum allowable working pres- sure (MAWP), The MAWP pressure shall be furnished by the purchaser. 9.2 ‘The recommended minimum hydrostatic test tem- perature is 70°F (21°C) 10, Marking, Packaging, and Loading 10.1 In addition to the marking requirements of Speci- fication A 788, the MDT and the MAWP shall be included together with any required application code marking, 10.2 Packaging and loading shall be done so that the forging is not damaged during shipment to the purchaser LL. Keywords ALA internal pressure: machinery—corrugating; roll assembly—forged; rolls—corrugating; rolls—pressure; steel forgings—atloy; steel forgings—earbon; steel rolls; surface-hardened; trunnions—bolted; trunnions— shrink-fitted2007 SECTION 11, PART A TABLE 1 CHEMICAL REQUIREMENTS Composition, 9% lass 18 Class 18 Glass 2 lass 3 Class 4 Glass 5 Carbon 05-060 0.40-0.60 0.58 max 0.38 max 0.35 max 050-0.60 Manganese 0.55-1.05 0.60-0.95 0.50-0.90, 0.40-0.70 0.80-1.05 0.90-2.50 Phosphorus 0.025 max 0.025 max 0.025 max 0.025 max 0.025 max 0.625 max Sulfur 0.025 max 0.025 max 0.028 max 0.925 max 0.025 max 0.028 max Silicon (A) 015-038 015-035, (015-035 max 015-035 0.15-0.35 max 0.5-0.35 Nickel 1.55-2.00 0.60 max Chromium 080-115 b65-0.95 ogo-113 0.30 max Malyoseaum 015-050 0.20-0.45 0.15-0.25 0.5 max Note: (A) When vacuum eatan deexidation (VCD) is used the sean content shal be 0.10% maximum TABLE 2 TENSILE REQUIREMENTS Yield Strength rin (AD “Tensile Stent, min Edeuanon bite Class Grade ts Ma. is Pa, py 50 mm, %, min Area, %, in 1a, 1B 0r 5S 1 130 390 150 2030 320 30 1A, 1B or 5 26) 6 450 209 690 140 30 z 378 260 75 515 200 50.0 Bora 30 205 6 25 22.0 55 notes: (8) 02% offset (8) For trunnion eoplication, @ maximum tensile stength of 125 ksi [860 Mal apples for Grade 2 of Clases 1A, 18, oF 5. 11762007 SECTION H, PART A 'SA649/84.649§, SUPPLEMENTARY REQUIREMENTS. ‘The following supplementary requirements shall apply only when specified by the purchaser fon the order and agreed to by the manufacturer: Sl. Surface-Hardened Corrugating Rolls SI.1_ Afterall surfaces have been machined, the outer sunface of the corrugating rolls may be surface-hardened to a surface hardness of Rockwell 53 HRC to 65 HRC, ‘The depth of hardness shall not exceed % in [95 mm. A ninimom of three hardness detesinations shall be made on the surface. Additional hardness tests shall be made to establish the depth of hardness. The hardened surface shall be magnetic paticle tested (see Section §), 52, Notch Toughness ‘$2.1 For applications where minimum notch tough- ness limits are required, impact testing shall be specified for un both sol bodies and trunnions. The following requirements shall be specifies 2.1.1 Type of impact specimen and test standard (for example, ASTM Test Methods and Definitions A 370 specimen Type A or B). $21.2 Minimuin value for absorbed energy ot lateral expansion. 82.13 Test temperature. S2.1.4 Frequency of testing. $2.2 Trunnion and pressure rolls may be liguid ‘quenched and tempered instead of the heat treatments spec- ified in 4.2 when impact testing is required.178