WHEMCO Inc.

1
WHEMCO Inc.

• The Largest Rollmaker in USA

HISTORY
2
PARK CORPORATION

• Whemco Inc. Owners PARK
  CORPORATION
• Private US company
• Financially rated Strong
• Dunn Brad Street rating 5A1 ( DB
  reference number 06-346-1115)
  
  
  
• 300 m turnover with 2500 employees

PARK CORP
3
Whemco Inc. Manufacturing
4
Lehigh Heavy Forge Corporation

• 100 years experience
• 250 t forgings
• Re built computerised oil hydraulic 10000 t press
  
• 4000t press
• Rolls up to 2000 mm dia145t maximum weight
• Supplier of all US Navy Forgings
• Bethlehem PA (1 hour Newark NJ)

FORGED ROLLS
5
Erie Forge and Steel Inc.

• Specialises in ship shafting
• Works in close co operation with LeHigh Heavy
  Forge inc
• Heat treatment of long shafts
• Machining of shafts up to 22 m
• Erie PA

6
Whemco Steel Casting Inc.

• 100 t arc furnace
• Rolls cast directly on to metal mould
• Back Up rolls are double poured A unique
  World Class product
• Selas Differentially Hardening
• Steel Industry castings including slag pots and
  stainless steel coiler drums.
• Midland Foundry Pittsburgh

7
Whemco Steel Casting Inc. Cast Back Up Rolls
Solidification

• Fast solidification against metal mould gives
  finer structures
• Excellent central soundness achieved by diluting
  core with a low alloy steel
• Combines best of static and duplex
  technologywith DH hardening
• Up to 6 cast BU and 4 Section produced per week

CAST BU ROLLS
8
Whemco Steel Casting Inc. Cast Back Up Rolls
Dilution Process
Bridging and segregation would occur if
solidification was not interrupted.
A hot lower alloy steel dilution of the core is
used to remove segregates
The improved temperature distribution allows
Progressivesolidification to continue
The final roll has an internal
Soundnessequivalent to Forged roll
9
Whemco Steel Casting Inc. Cast Back Up Rolls
Hardening Process

• ALL BU rolls differentially hardened using a
  Selas furnace
• Largest hardening unit in US and Europe
• Unique double hardening treatment for 5 Cr BU
  rolls
• Tough centre allows severe water quench to give
  up to 125 mm radial hardened depth

10
Whemco Steel Casting Inc. Cast Back Up Rolls
Size capability
          Recommended Recommended
  Grade Max Dia Cast Heat Hardness range Shore C Hardness range Shore C
Type Cr mm Method Treatment Min Max
             
Cast 3 1650 Diluted DH 58 70
Cast 5 1650 Diluted DH 60 75
11
Whemco Ohio Foundry Inc.

• Spin casting technology
• Rolls size up to 1100 mm
• Rolls for hot strip mills
• CNC finishing lathes
• Static Cast Iron BU and Plate mill rolls
• Ohio foundry at Lima Ohio

12
Whemco Ohio Foundry Inc.

• Investment programme
• Melting furnaces
• Computer modelling usedto ensure product
  consistency
• Thermal analysis of each melt carried out to
  ensure consistency.
• Produce full range of alloy white irons IC
  HiCr and enhanced carbide rolls

13
Whemco Ohio Foundry Inc.High Chromium Irons
Shell
TC Si S P Mn Ni Cr Mo
Shell
HCI Hot mill 2.40 0.50 0.02 0.04 0.65 0.40 16.50 1.00
2.70 0.75 max max 0.85 0.85 17.50 1.55
14
Whemco Ohio Foundry Inc.High Chromium Irons
Cores
TC Si S P Mn Ni Cr Mo Mg
Core
Flake 2.80 1.20 0.05 0.06 0.40 lt2.00 lt0.20
3.00 1.60 max max 0.60

SG 2.80 1.20 low 0.06 0.20 lt2.00 lt0.20 lt0.08
3.00 2.00 max 0.40

15
Whemco Ohio Foundry Inc.IDCP Shells NHI Grades
TC Si S P Mn Ni Cr Mo
Shell
NHI-450 3.10 0.85 0.05 0.06 0.40 4.50 1.50 0.30
3.50 1.10 max max 0.50 5.00 1.90 0.50

NHI- Tec 3.10 0.85 0.05 0.06 0.80 4.50 1.50 0.30

3.50 1.10 max max 1.00 5.00 1.90 0.50
16
Whemco Ohio Foundry Inc.IDCP Shells NHI Hardness
Typical Hardness Range Typical Hardness Range Typical Hardness Range Typical Hardness Range
Equitip Ld Equitip Ld Equitip Ld Equitip Ld

Shell
NHI-450 770 790

NHI-450M 770 800
17
Whemco Ohio Foundry Inc.Developments

• New 5T and 2T furnaces will allow production of
  enhanced carbide and HSS rolls.
• Enhanced carbide rolls with weights above 12500
  kgm are already been produced.
• Triple pour HSS rolls will be produced in 2006

18
Duraloy Technologies Inc.

• Horizontal spin casting of heat resisting steels
• Petrochemical reactor tubing
• Tunnel furnace rollers
• Plate hardening furnace rollers
• Scottdale PA
• ( 1hr South Pittsburgh)

19
Duraloy Technologies Inc. Tunnel Furnace Rollers
(CSP mills)

• Wet Rollers
• Used in heating zones
• 28 Cr 48 Ni plus W
• Refractory coated only tyre in contact
• Operate up to 1260 ºC

20
Duraloy Technologies Inc. Tunnel Furnace Rollers
(CSP mills)

• Dry Rollers (Ni Cr Co W alloys)
• Replace wet rollers in shuttle zone.
• 10 less purchases for warping and refractory
  replacement
• Dry rollers in use gt2years
• Less energy used. Typically 85 k euro/yr
• Reduced water treatment costs

21
Steckel Mill Coiler Drums

• High temperature cast alloy 20 Cr 30 Ni
• Resists deformation / crack propagation / scale
  pickup
• Thermo-mechanical stress analysis
• Extends campaign life / reduces repair cost
• Advanced foundry technology
• Produces largest size drum casting in the world

BU
Structure
22

• UK Registered Company
• Employees not agents (Currently 2)
• Whemcos face in Europe
• All enquiries / questions handled from UK
• All service handled from UK Next day response
• Commercial and Technical Decisions taken on the
  spot no need for reference to US

23
Whemco Inc. Summary Roll capabilities
Barrel Barrel Barrel    
Min Dia. Max Dia. Max Length Max Total Max Finished
mm mm mm length mm Weight Kgm.
     
Cast BU Rolls 800 1650 3900 6350 65,000
       
Forged BU Rolls 800 2000 4000 7000 145,000
       
Spun Cast Work Rolls 500 1100 3350 5350 15,000
       
Forged Work Rolls 400 800 2250 4000 12,000
24
Whemco Inc. Summary Key Strengths

• Financially strong corporate structure
• 3rd largest Rollmaker in the western world
• Manufacturer of unique range of World Class
  cast BU rolls
• Largest Forgemasters in the western world
• Target is a long term development of export sales
  and Service

25
WHEMCO Inc.

• The Largest Rollmaker in USA

We are here to answer any Questions