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Failure Analysis of Cast Iron Overlay Material in Grinding Rollers by SEM/EDS and XRD Characterization

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Abstract:

Grinding rollers are critical components of the cement manufacturing process, with the grinding rollers experiencing heavy mechanical and chemical stresses that can cause early failure. The present research aimed to analyze a failed roller specimen, which included a backing material and an overlay layer, to determine the root causes of deterioration. The research method adopted combined visual examination, Scanning Electron Microscopy (SEM), Energy Dispersive X-ray Spectroscopy (EDS), and X-ray Diffraction (XRD) analysis. Macroscopic investigation determined pitting, cracking, heavy corrosion, and wear patterns on the overlay material. Investigations by SEM/EDS found significant concentrations of chlorine (Cl) and sulfur (S) within the damaged interface and within fissures, consequently proving their roles as potent corrosive agents. Moreover, oxygen (O) was detected in substantial amounts, advocating massive oxidation processes. The results of the XRD examination of the corroded area revealed products of corrosion that correspond to oxide and chloride phases. The results demonstrate that grinding roller failure results from a combined effect of mechanical fatigue and chemical corrosion, with specific vulnerability being evident in the overlay layer. The outcome emphasizes the need for better material selection, optimal overlays deposition, and the utilization of protection treatments to enhance the service life of grinding rollers within the cement manufacturing industry.

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Periodical:

Defect and Diffusion Forum (Volume 453)

Pages:

61-71

DOI:

https://doi.org/10.4028/p-i4WhRO

Citation:

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Online since:

July 2026

Authors:

Nebbar Mohamed Chaouki*

Keywords:

Cement Industry, Corrosion, Energy Dispersive X-Ray Spectroscopy, Failure Analysis, Grinding Rollers, Scanning Electron Microscopy, X-Ray Diffraction

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© 2026 Trans Tech Publications Ltd. All Rights Reserved

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* - Corresponding Author

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