Benefits of Using Powder Metal Advanced Materials for

Benefits of Using Powder Metal Advanced Materials for Rolling Mill Applications John D Hunter, Carpenter Powder Products, Inc. Gregory J Del Corso, Carpenter Powder Products, Inc. David J Novotnak, Carpenter Powder Products, Inc. Unless otherwise noted, the logo and registered trademarks are property of CRS Holdings, Inc. a subsidiary of Carpenter Technology Corporation. © 2012 CRS Holdings, Inc. All rights reserved

Presentation Outline • Manufacturing PM Materials – What is Gas Atomization? – Why gas atomize powders? – Gas atomized powder uses • Manufacturing PM Rolls – Process – History in the Carpenter Reading Mill – Types of rolls using PM materials • Benefits of using PM Rolls – Improved product quality and reduced costs • Questions? © 2012 CRS Holdings, Inc. All rights reserved 2

What is Gas Atomization? • A process to convert molten metal into powder particles

Photo of Gas Atomization Process © 2012 CRS Holdings, Inc. All rights reserved

Gas Atomized Metal Powder © 2012 CRS Holdings, Inc. All rights reserved

Range of High Purity Ni, Fe & Co. Based Alloy Powders Applications: • Hot Densification Ø HIP'g, Extrusion, Dynaforge, etc. • Surfacing, Hardfacing & Joining Powders • Metal Injection Molding • Additive Manufacturing Ø Laser Sintering, Rapid Diversified Powders for Customer Satisfaction Prototyping, etc. © 2012 CRS Holdings, Inc. All rights reserved 6

Why Produce Gas Atomized, Prealloyed Metal Powders? Ø To produce powders for use in downstream loose powder processes Ø To produce alloys that cannot be produced via ingot metallurgy processes Ø To produce consolidated products that: v Have improved performance over ingot metallurgy products due to refined microstructure v Cannot be produced by conventional ingot metallurgy processes v Are cost-effective © 2012 CRS Holdings, Inc. All rights reserved 7

Carpenter’s Micro-Melt® Process & Typical Products © 2012 CRS Holdings, Inc. All rights reserved

Carpenter’s Micro-Melt PM Process Over 40 years of experience in the production of gas atomized powders Most diversified gas atomized powder producer in the world Standard and customized alloy systems to exceed the needs of the customer © 2012 CRS Holdings, Inc. All rights reserved 9

Product Forms for Carpenter’s Metallic Powders © 2012 CRS Holdings, Inc. All rights reserved

Manufacturing Monolithic and Composite Rolls PM Process Flow

CPP Powder Screening CPP screens powder to customer specified mesh sizes © 2012 CRS

CPP Powder Blending CPP can blend multiple batches of powder metal into one uniform

CPP Manufacturing Process – Load/Degas/Seal Powder Blends are filled into canisters, degassed & sealed prior to consolidation by hot isostatic pressing (HIP’g) © 2011 CRS Holdings, Inc. All rights reserved 14

Carpenter Powder Products Typical HIP Units © 2012 CRS Holdings, Inc. All rights reserved

Hot Isostatic Pressing - HIP > 1100° C ≈ 1000 bar Time – several

Micro-Melt M 4 HSS AISI M 4 Alloy 1. 5 C-4. 5 Cr-4. 5 Mo-5. 5 W-4. 0 V-0. 4 Mn-0. 4 Si -0. 12 S Cast/Wrought Bar stock P/M Bar stock Microstructures of Hot Rolled + Finished Bar Longitudinal Section; 100 X; Etchant: Vilella’s © 2012 CRS Holdings, Inc. All rights reserved 17

As-HIP’d Product Applications • Valve Body • Venturi Valve • Heat Exchanger Parts •

Common TS Alloy Names Cross References • AISI A-11 – UNS T 30311 - Micro-Melt® A 11 or CPM® 10 V • Micro-Melt® A 11 -LVC or CPM® 9 V • AISI M-4 – UNS T 11304 - Micro-Melt® M-4 • AISI T-15 – UNS T 12015 - Micro-Melt® T-15 – CPM® 10 V and 9 V are trademarks of Crucible Industries – Micro-Melt® is a trademark of CRS Holdings, Inc a subsidiary of Carpenter Technology Corporation © 2012 CRS Holdings, Inc. All rights reserved

Manufacturing PM Clad Rolls © 2012 CRS Holdings, Inc. All rights reserved 20

HIP’d Bi-Metallic Roll • 100% Metallurgical Bond Between Dissimilar Alloys without melting. • 100% Fully Dense after HIP. • Very low dilution with substrate. • Near Net shape components possible. • Multiple alloy and layer combinations. • Combines strengths of both alloys. © 2012 CRS Holdings, Inc. All rights reserved 21

HIP’d Bi-metallic or Composite Clad Roll • • Micro-Melt® powder metal clad layer Alloy steel shaft Uniform microstructure Fine carbide particle size Homogenous through hardness within clad layer Metallurgical bond at interface Greatly increased roll life Diagram courtesy of Sinter. Met, LLC © 2012 CRS Holdings, Inc. All rights reserved

Bimetallic Rolls for our No. 5 Hot Mill A 11 LVC clad rolls for

History of using PM/Clad Rolls in Reading Mill • • • PM rolls introduced in mid to late 1990’s in the Strip Finishing Dept for the cold rolling mill work rolls. In 2001 Maxamet® rolls were introduced on the 14” Z Mill. Some of those bought in 2006 are still in use. In 2001 A 11 LVC Composite rolls were placed in service on the No 5 Hot mill stands 15 & 16. In 2004 placed 4 sets on 13 & 14 stands – all sets still in service. In 2008 implemented 11 & 12 stands open rounds and breakdown ovals – 1 set each and both still in service. 2009 implemented same on 9 & 10 stands, still in service © 2012 CRS Holdings, Inc. All rights reserved

PM Rolls – Composite & Monolithic • • Plate Strip Angle Rebar • • • Guide Looper Table Straightener 3 mill or Kocks mill Turks head Photos courtesy of Leadar Rolls © 2012 CRS Holdings, Inc. All rights reserved

Benefits of Using PM Clad Rolls • Improved Product Quality – Surface quality is increased – More consistent product is produced • Reduced Mill Down Time – PM/Clad rolls have shown an average of 5 times the life of traditional rolls – Longer time between dressing rolls and greater number of dresses possible for example: • Prior 3 traditional rolls, averaged 10. 7 dresses (No. 5 Mill) • Current PM/Clad roll is at 16 dresses at 2. 3 times the average tons/dress and it is still in use! – Obviously every mill stoppage which can be avoided saves a great amount of money! © 2012 CRS Holdings, Inc. All rights reserved

Benefits of Using PM Clad Rolls • Reduced Costs: – On roll design for our No. 5 Mill Clad rolls cost 29. 1% of the price of traditional rolls (per ton of material rolled). – Another example shows the PM/Clad rolls cost 46. 8% of the traditional rolls – although the set of clad rolls is still in service, so will continue to lower this percentage. – Finally, a third example shows the PM/Clad rolls cost only 36. 4% of the traditional rolls per ton of material rolled. – All of the above data was collected by Reading plant personnel on the No. 5 Hot mill. • The payback for PM/Clad rolls is estimated by another CPP customer at less than 30 days even with their approximate 4 x higher initial cost as the mill uptime is improved so much! © 2012 CRS Holdings, Inc. All rights reserved

Benefits of Using PM/Clad Rolls • Questions? • Thanks to all those who have helped by contributing data, comments, and their expertise in putting this presentation together including Cartech Reading personnel and our friends at Leadar Roll, Sinter. Met, and United Foundries. Disclaimer Applications suggested for material described herein are made solely for the purpose of illustration to enable the reader to make his/her own evaluation and are not intended as warranties, either express or implied, of fitness for these or other purposes. Alloy performance data presented are typical or average values and are not a guarantee of maximum or minimum values. © 2012 CRS Holdings, Inc. All rights reserved